Ambirad NRV12LR, NRV18LR, NRV24LR, NRV32LR, NRV38LR User guide

...

Download

Page 1

ASSEMBLY, INSTALLATION & SERVICING

ANUAL FOR AMBIRAD NOR-RAY-VAC

ONTINUOUS RADIANT TUBE SYSTEM

INDEX Section

Introduction and Document Index Installation Requirements-------------------------------------------------1 Assembly Instructions------------------------------------------------------2

Commissioning Instructions----------------------------------------------3 Servicing Instructions------------------------------------------------------4 Spare Parts-------------------------------------------------------------------5 Fault Finding Guide --------------------------------------------------------6 Replacing Parts -------------------------------------------------------------7 User and Operating Instructions ----------------------------------------8

WARNINGS

AmbiRad equipment must be installed and maintained in accordance with the relevant provisions of the Gas Safety (Installations and Use) Regulations 1998 for gas fired products. Due account should also be taken of any obligations arising from the Health and Safety at Works Act 1974 or relevant codes of practice. In addition the installation must be carried out in accordance with the current IEE wiring regulations (BS 7671), BS 6896 (Industrial & Commercial) and any other relevant British Standards and Codes of Practice by a qualified installer. All external wiring MUST comply with the current IEE wiring regulations.

Page 2

Document Index.

1 Installation Requirements

1.1 Health & Safety

1.2 Burner Model Definitions

1.3 Heater Suspension

1.4 Clearance to Combustibles

1.5 Gas Connection & Supply Details

1.6 Electrical Connections

1.6.1 Typical Wiring Schematic

1.6.2 Wiring Details

1.7 Ventilation Requirements

1.8 Exhaust & Air Inlet Options

1.8.1 Exhaust Flue Considerations

1.8.2 Ducted Air Inlet Considerations

1.9 Vacuum Fan Details

1.10 Technical Data

2 Assembly Instructions

2.1 Tools Required

2.2 Assembly Notes

2.2.1 Tubes

2.2.2 Couplers

2.2.3 Reflectors

2.2.3.1 Main Reflectors

2.2.3.2 Perimeter Reflectors

2.2.3.3 Corner Reflectors

2.2.3.4 Tee Reflectors

2.2.4 Brackets

2.2.4.1 Suspension Brackets

2.2.4.2 Reflector Support Brackets

2.2.5 Burner

2.2.5.1 LR Burner

2.2.5.2 Burner Head

2.2.6 End Vent Module

2.2.7 Exhaust Fan

2.3 Installation of End Vent/In-line Section

2.4 Installation of Radiant Tube to Tail Pipe

2.5 Installation of Main Reflectors

2.6 Installation of Corner Reflector

2.7 Installation of Tee Reflector

2.8 Final Fixture and Adjustments

2.9 Installation of Fan Exhaust System

2.9.1 Vertical Discharge

2.9.2 Horizontal Discharge

2.9.3 Fan Mounting

2.9.4 Condensate Trap

2.10 Full Breakdown of Typical System

2.11 Installation of End Vent and In-line Burners

2.12 Installation of End Vent Module (EVM)

2.13 Installation of Ducted Air Adaptors

2.13.1 Burner Assembly Adaptor

2.13.2 End Vent Module Adaptor

2.14 Installation of Ball Guard System

2.14.1 Installation

2.14.2 Blanking Shield

2.15 Installation of Slimline Decorative Grille System

2.15.1 Standard Modular Assembly

2.15.2 Shortened Assemblies

2.16 Installation of Blanking Shields

2.17 Installation of Undershield Deflectors

2.18 Installation of Vacuum Fan Acoustic Booth

2.18.1 Dis-assembly

2.18.2 Re-Assemble

2.18.3 Suspension instructions

2.19 Fan Exhaust Silencer

2.19.1 Assembly

2.19.2 Horizontal Configuration

2.19.3 Vertical Configuration

2.20 Fan Motor Muff

2.21 End Vent Silencer

3 Commissioning Instructions

3.1 Tools Required

3.2 General

3.3 Commissioning Procedure

3.3.1 Start Up Checks

3.3.1.8 Burner Timer Dip-switch Settings

3.4 B80/B160 & B300 Inverter Set Up

3.5 BH300 Non-Inverter Set Up

3.6 Final Commissioning

3.7 Typical Unequal Balanced System Layout

4 Servicing Instructions

4.1 Tools Required

4.2 Burner Exploded Views

4.3 Vacuum Fan

4.4 Radiant Tubes

4.5 Tube Couplers

4.6 Reflectors

4.7 Flue Condensate

4.8 Burner Electrodes

4.9 Burner Head

4.10 Filters

4.11 Combustion Chamber Viewing Window

5 Spare Parts

5.1 Required Spares List

5.2 Injector/Air Shutter Selection

6 Fault Finding Guide 7 Replacing Parts

7.1 Removal of Burner Assembly

7.2 Gas Valve Replacement

7.3 Filter Replacement

7.4 Controller Replacement

7.5 Pressure Switch Replacement

7.6 Sequence Timer Replacement

7.7 Electrode Assembly Replacement

7.8 Injector Replacement

7.9 Combustion Chamber Window Replacement

8 User and Operating Instructions

8.1 To Start Heater

8.2 To Switch Off Heater

8.3 Routine Maintenance Between Service Intervals

8.4 Frequency of Servicing

Page 3

Introduction.

Welcome to the range of Nor-Ray-Vac ‘LR’ series continuous radiant tube heaters. The Nor-Ray-Vac ‘LR’ series system complies with the requirements of the European Gas Appliance Directive BS EN777-4. Local regulations may vary in the country of use and it is the installers responsibility to ensure that such regulations are satisfied.

All installation, assembly, commissioning and service procedures must be carried out by suitable qualified competent persons to the statutory regulations in the country of use.

When assembling, installing, commissioning and servicing is undertaken on radiant tube heaters specified in these instructions, due care and attention is required to ensure that working at height regulations are adhered to at the mounting heights specified.

PLEASE READ this document prior to

installation to familiarise yourself with the components and tools you require at the various stages of assembly.

All Dimensions shown are in mm unless otherwise stated.

The manufacturer reserves the right to alter specifications without prior notice.

The Ambi-Rad Nor-Ray-Vac ‘LR’ series direct gas fired radiant heating system comprises of a continuous system with a number of burners located in series in a radiant branch, and a

number of radiant branches manifolded together, linked by a tail pipe to a vacuum fan discharging the spent products of combustion to atmosphere. A system may comprise of just one burner and one vacuum fan, to multiple burners in multiple radiant branches with one or more vacuum fans.

To enable exact matching of operational needs within an area, distances between burners and ratings of the burners can vary. The unique feature of Nor-Ray-Vac ‘LR’ series is a radiant system which provides uniform heat coverage of the floor area, eliminating hot/cold spots.

The tube into which the burners are mounted and over which the reflectors are fitted and emits the maximum heat is called the radiant tube. The radiant heat emitted from the hot tube is directed downwards by reflectors. The remaining interconnecting tube is called the tail pipe and radiates with less intensity.

The operating temperatures of the tubes generally range from 200°C – 480°C max.

The action of the vacuum fan is three fold; to create a high negative pressure within the radiant tube and tail pipe so as to discharge the spent products of combustion from the system to a point outside the building being heated; to control the flow of gas and air through each burner in stoichiometric proportions; to draw carrier air into the tube system at the start of each radiant branch, in order to distribute the heat from the flame along the tube.

1. Installation Requirements.

Isolate any electrical supply to the heater and controller before proceeding.

1.1 Health and Safety

AmbiRad heaters must be installed in accordance with the relevant provisions of the Gas Safety (Installations and Use) Regulations

1998. Due account should also be taken of any

obligations arising from the Health and Safety at Works Act 1974 or relevant codes of practice. In addition the installation must be carried out in accordance with the current IEE wiring regulations (BS 7671), BS 6896: (Industrial & Commercial) and any other relevant British Standards and Codes of Practice by a qualified installer. Isolate all electrical supplies to the heater & controller before proceeding.

For your own safety we recommend the use of safety boots and leather faced gloves when handling sharp or heavy items. The use of protective eye wear is also recommended.

1.2 Burner Model Definitions

NRVxxLR-EV = Nor-Ray-Vac continuous

radiant tube heater only for use with branch end configurations. NRVxxLR-IL = Nor-Ray-Vac continuous radiant tube heater only for use with in-line configurations.

xx denotes kW rating. Models available; 12, 18, 24, 32, 38 and 46

The system is assembled at high level suspended by chains from first fixings to the roof structure. (First fixings by others)

Page 4

1.3 Heater Suspension

1.3.1 First considerations

• Clearances from combustibles must be

maintained. (See figure 2)

• For ease of servicing there should be a

minimum clearance distance of 500mm

between the burners of the heating system and the building wall. This measurement can be reduced for perimeter type systems. (See figure 1a).

• For ease of servicing and burner removal

minimum clearances should be maintained. (See figure 1b and 1c). In exceptional circumstances the burner lid may be slid diagonally for removal thus reducing the vertical distance.

• Ensure that the suspension is sufficiently

flexible to allow for thermal expansion.

1.3.2 Suspending the heater - General

1.3.2.1 The first support is always positioned at

the support lug suspension point on the end vent burner combustion chamber.

1.3.2.2 Subsequent supports are placed approximately 2.8m apart, including one at each combustion chamber location. This gives a maximum load per support of 24kg.

1.3.2.3 A support must always be located at a maximum distance of 2m from a tee or elbow fitting.

1.3.2.4 Except for the combustion chamber support lug suspension points, suspension support brackets are installed to support the tube section which is then covered with reflectors.

1.3.2.5 Tail pipe hangers are installed for the tube section which will be without reflectors.

If there are any doubts as to the strength or suitability of roof steelwork to which heaters are to be suspended, please refer to a Consultant, Architect or owner of the building.

Table 1. Minimum mounting heights

Model

NRV12LR NRV18LR NRV24LR NRV32LR NRV38LR NRV46LR

Minimum Mounting

Heights (m)

3.0m

3.6m

4.0m

4.7m

5.3m

6.0m

Figure 1.a Overall Dimensions

A - Burner Tube B - LR Burner

C - Optional Perimeter Reflector

D - Wall

(100mm MIN - Perimeter Systems)

Page 5

Figure 1.b Clearance for servicing - distances to walls and obstacles above.

Figure 1.c Clearance for servicing - distances to obstacles above.

E - Obstacle over burner F - End vent module G - Burner lid

Page 6

1.4 Clearance to Combustibles.

The minimum clearances to combustible materials are given in table 2 below. These minimum distances MUST be adhered to at all times.

Figure 2 Diagram illustrating the clearance to combustibles

Distance from combustibles (distance from heat source that will produce a 50ºC rise in temperature above ambient of a black surface) A Radiant tube; B Standard reflector; C Combustible material underneath; D Combustible material on side;

E Combustible material above; F Perimeter reflector;

Table 2

Burner Model NRV12LR NRV18LR NRV24LR

End vent In-line End vent In-line End vent In-line

Below tube

Dim D Dim D Dim C

Horizontally

Dim B Dim A

Without undershield mm 1120 1250 1120 1250 1120 1250 With undershield mm 760 850 760 850 760 850 Above Tube mm 250

Standard reflector mm 600 770 600 770 600 770

Perimeter reflector mm 305 450 305 450 305 450 Burner Model NRV32LR NRV38LR NRV46LR End vent In-line End vent In-line End vent

Below tube

Dim D Dim D Dim C

Horizontally

Dim B Dim A

Without undershield mm 1440 1700 1570 2100 1700 2100

With undershield mm 760 850 785 1050 850 1050

Above Tube mm 250

Standard reflector mm 700 850 700 1000 700 1000

Perimeter reflector mm 305 510 305 600 305 600

Page 7

1.5 Gas Connection and Supply

Before installation, check that the local distribution conditions, nature of gas and pressure, and adjustment of the appliance are compatible.

A competent or qualified engineer is required to either install a new gas meter to the service pipe or to check that the existing meter is adequate to deal with the rate of gas supply required.

Installation pipes should be fitted in accordance with BS 6896, so that the supply pressure, as stated in Table 3 will be achieved. It is the responsibility of the competent engineer to ensure that other relevant Standards and Codes of Practice are complied with in the country of installation.

Pipes of smaller size than the heater inlet gas connection must not be used. The complete installation must be tested for soundness as described in the country of installation.

The gas union service cock MUST be fitted in the gas supply close to the heater, but not onto the burner itself.

Take care when making a gas connection to the heater not to apply excessive turning

force to the internal controls.

A flexible hose is installed to allow safe linear expansion to each burner without creating undue stress on the gas supply pipe work. It is therefore important that a tested and certified hose assembly made to ISO 10380, supplied with ½” BSP female cone seat adapters, is installed as per these instructions.

It is also important to ensure that expansion is taken up in the body of the flexible hose, and not on its attachment to the pipe work.

The cone seat adapter supplied on one end of the flexible gas hose provides a `swivel` action, and must be fitted on the burner using a ½” BSP barrel nipple to provide ease of disconnection for future servicing.

The installation layout described below is

the only method recommended by the institute of gas engineers, the hose manufacturer, and AmbiRad and must only be carried out by a qualified/competent gas engineer.

Table 3 Gas Supply Pressures

Gas Category

Gas Type

Max Supply Pressure (mbar) Min Supply Pressure (mbar) Nominal Pressure (mbar) Gas Supply

G20 G31

Natural Gas Propane

50 57.5

17.5 25 20 37

G25

Natural Gas

50 20 25

G30

Butane

35 20 29

Connection R½ ½in BSP Internal Thread

Page 8

Figure 3. Correct Installation of Flexible Gas Connection

fig.a

fig.b

Depending on the specific installation, the flexible gas hose may be routed to the gas cock at any of the following angles in relation to the burner:

Vertical (fig.a) 45° angle (fig.b) 90° angle (fig.c)

Any other position in between these angles is acceptable.

Care must be taken to observe the minimum pipe bend diameter (minimum 250mm, maximum 350mm) & pipe expansion distance (minimum 30mm, maximum 70mm) as shown in fig.e.

Maximum bend diameter for the hose is 450mm.

The correct installation as shown will allow for approx 100mm of movement due to

expansion.

Arrow denotes direction of expansion.

fig.d

50 +/- 20mm

Burner

fig.c

400 +/- 50mm

fig.e

fig.f

fig.g

The methods shown in fig.f and fig.g are unacceptable, due to undue stress on the hose & fittings.

Page 9

1.6 Electrical Connections

Standard burner 16W. Current rating 0.05 amp per burner Fuse: external 3 amp.

Each component carrying an electrical supply must be earthed.

Supply for burners is 230V 50Hz single

phase. * Exhaust fans are three phase 415V 50Hz. * IP54 rated Inverter panel LRU’s require a 230V single phase supply at 22A (B80/ B160) or 30A (B300) * Standard LRU’s require a 415V three phase supply at 25A (BH300)

* refer to individual site specifications

All electrical work should be carried out to IEE standards by a competent electrician.

The electrical connection to the burner is made by means of a three pin plug-in power connector. Live, neutral and earth connections should be made via a flexible supply cable to the power connector and routed clear of the heater or tubes.

The flexible supply cables to each burner

should be of 0.5mm² minimum and comply with BS 6500:2000. For

fan and LRU supply, the wire size must be suitable for the current ratings as listed in Table

10. The wires in the mains

lead are coloured in accordance with the following code: Green & Yellow Earth; Blue Neutral; Brown Live

The method of connection to the electrical supply must facilitate complete isolation and should be via a fused double pole isolator having contact separation of at least 3mm on all poles and supplying the appliance only.

We recommend use of AmbiRad approved controls. Please refer to; SmartCom control

manual for siting and installation details and figures 4.l and 4.m

Where alternative controls are used, please refer to the manufactures instructions for their siting and installation details.

Figure 4.a. Typical Wiring Connections

‘Power out’ from

End Vent Burner to

In-line Burner(s)

End Vent Burner

To other

in-line burners

Fused Spur

In-line Burner

Fused Spur

230V 50Hz Switched Supply from Control Source

Page 10

1.6.1 NRV LR system - Typical External Diagram

Zone 2

Sensor

Screened

Cable

Isolator

SmartCom³ no.2

‘Slave’ (SC3-MZ)

Mains Supply

230V 50Hz 13A

Module

End Vent

Fused

0.75mm²

Burner

* IMPORTANT

Inverter and Fan is 5m

For Inverter Panels only

(fan types B80/B160 & B300)

MAXIMUM length of cable between

Fused Spur

Burner to In-line Burners

From ‘Power out’ on End Vent

In-line Burner

1st Branch Zone 2

In-line Burner

Fused Spur

Tail Pipe

In-line Burner

Fused Spur

1st Branch Zone 1

Fan types B80/B160 & B300)

MOTOR MUST BE WIRED IN

DELTA.

IMPORTANT

In-line Burner

Fused Spur

* 4 core

Armoured Cable

Isolator

Local Relay

Zone 1

Sensor

0.75mm²

Screened

Cable

Unit / Inverter

Panel

Networking Cable

Screened pair Beldon

Isolator

9841 or equiv

SmartCom³ no.1

‘Master’ (SC3-MZ)

2nd Branch Zone 1

In-line Burner

Fused Spur

From ‘Power out’ on

End Vent Burner to

In-line Burners

From ‘Power out’

on End Vent Burner

End Vent

ers

to In-line Burn-

End Vent

Module

End Vent

Module

End Vent

Fused Spur

To ‘Mains In’ on

End Vent Burner

Mains Supply

230V 50Hz 13A

To ‘Mains In’ on

End Vent Burner

Page 11

1.6.2 Wiring Details Figure 4.c. LR internal wiring diagram - End Vent Burner (EV)

SOLENOID VALVE

POWER OUT

3 2

VALVE

J.S.T.

MAINS INPUT

EMC FILTER

GREEN/YELLOW

BLUE

GREEN/YELLOW

BLUE

GRN/YEL

LAMPS

MAINS

BURNER

RED BLUE BLUE

RED

BLUE

IGNITOR

FLAME SENSOR

BLACK

PURPLE

BROWN

3 2

RED

DELAY TIMER

2345

MAIN J.S.T.

11 10

RED

GREY

BLACK

VACUUM SWITCH

N.O.

N.C.

Figure 4.d. LR internal wiring diagram - In-line Burner (IL)

MAINS INPUT

SOLENOID VALVE

3 2

VALVE

J.S.T.

EMC FILTER

GREEN/YELLOW

BLUE

GRN/YEL

BLUE

LAMPS

MAINS

BURNER

RED

BLUE

BROWN

IGNITOR

FLAME SENSOR

PURPLE

3 2

MAIN J.S.T.

RED

DELAY TIMER

12345

BLACK

Page 12

Figure 4.e. LR internal wiring diagram - End Vent Burner c/w N/O or N/C volt free Lockout contacts

MAINS INPUT

L2 L1

Detail shows either N.O. or N.O. contacts

SOLENOID VALVE

POWER OUT

3 2

VALVE

J.S.T.

EMC FILTER

RELAY

N.O.

N.C.

BLUE

GREEN/YELLOW

IGNITOR

GRN/YEL

BROWN

BLUE

LAMPS

MAINS

GREEN/YELLOW

BLUE

BURNER

BROWN

DELAY TIMER

FLAME SENSOR

BLACK

PURPLE

3 2

RED

MAIN J.S.T.

GREY

BLACK

2345

RED

RED BLUE BLUE

VACUUM

RED

SWITCH

N.O.

N.C.

Figure 4.f. LR internal wiring diagram - In-line Burner c/w N/O or N/C volt free Lockout contacts

MAINS INPUT

Detail shows either N.O. or N.O. contacts

SOLENOID VALVE

3 2

VALVE

J.S.T.

EMC FILTER

N.O.

N.C.

RELAY

GREEN/YELLOW

BLUE

GRN/YEL

LAMPS

MAINS

BURNER

RED RED

BLUE

IGNITOR

FLAME SENSOR

PURPLE

BROWN

3 2

BLACK

MAIN J.S.T.

RED

DELAY TIMER

BROWN

12345

Page 13

Figure 4.g. LR internal wiring diagram - End Vent Burner c/w 3 way solenoid valve

3 WAY AR

SOLENOID

2 1

SOLENOID VALVE

POWER OUT

3 2 1

VALVE

J.S.T.

MAINS INPUT

EMC FILTER

BLUE

GRN/YEL

RED

BLUE

IGNITOR

GRN/YEL

BROWN

BLUE

LAMPS

MAINS

GREEN/YELLOW

BLUE

BURNER

BROWN

DELAY TIMER

FLAME SENSOR

BLACK

PURPLE

3 2

RED

MAIN J.S.T.

RED

BLACK

GREY

2345

RED BLUE BLUE

VACUUM

RED

SWITCH

N.O.

N.C.

Figure 4.h. LR internal wiring diagram - End Vent Burner c/w valve & N/O or N/C VF Lockout contacts

3 2

VALVE

J.S.T.

EMC FILTER

N.O.

N.C.

BLUE

RELAY

GRN/YEL

BLUE

LAMPS

MAINS

BLUE

BURNER

RED RED

BLUE

POWER OUT

BLUE

GRN/YEL

RED

IGNITOR

FLAME SENSOR

BLACK

PURPLE

BROWN

3 2 1

DELAY TIMER

VACUUM SWITCH

MAIN J.S.T.

RED

BLACK

GREY

2345

N.O.

N.C.

MAINS INPUT

SOLENOID VALVE

3 WAY AR

SOLENOID

2 1

GRN/YEL

BLUE

Page 14

Figure 4.j. NRV Inverter Internal Wiring Diagram for B80, B160 and B300 three phase fans

Green/Yellow

230V 50Hz

1 Ph Supply

LEN

230V 50HZ 1 Pha SUPPLY

Brown

15V LI1

Orange

t1 t2

3Ph Supply

To Fan

Circuit

VF Enable

MAINS ON LAMP

R/L1

Violet

Circuit

Fan Trip

V.S.D.1

AI10V

t3 t4

Brown

S/L2

Brown

W/T3

V/T2 U/T1

tW tV tU

FAN HEALTHY LAMP

Blue

TO FAN

NL NL

VUW

TERMINAL RAIL

Figure 4.k. NRV Local Relay Unit Internal Wiring Diagram for BH300 three phase fans

312

Green/Yellow

Grey

Black

415V 50Hz

3 Ph Supply

321

415V 50HZ 3 Pha SUPPLY

Brown

3 2 1

3Ph Supply

LEN

To Fan

t1 t2

98 97

Brown

t4 t3

Circuit

VF Enable

MAINS ON LAMP

95 A214

Contactor

96 A113

Brown

Circuit

Fan Trip

FAN HEALTHY

6 4 2

TO FAN

tV tW

Blue

3211

NL NL

VUW

TERMINAL RAIL

Page 15

Figure 4.l. NRV Schematic interconnecting wiring. B80, B160 and B300 three phase fans controlled by SmartCom3 via single phase Inverter panel. (single zone shown)

Zone A

burners

Supply to inline

Burners

frost etc).

therefore all wiring to the control must be

should be connected by 6A mains

enable).

Max length is 100m.

Low voltage switching inputs to be

normally open (closed circuit to

LIVE

Connect to B0 & B1 for remote ON

NOTES:

REMOTE SWITCH INPUTS

NEUT

SmartCom

Singlezone

*The power supply is non-isolated,

Connect to B0 & B2 for remote

OFF (ie door interlock. remote

(ie BMS time control).

B1 B0 B2 S/R0S/R1

41 40 9 5 1/L 2/N 10

mains rated.

from the control unit, using

REMOTE SENSOR(s) may be

placed at a max distance of 100m

Black Bulb

(REMOTE OFF)

(COMMON)

(REMOTE ON)

(NEUTRAL)

(LIVE)

(FAN CIRCUIT)

screened 6A mains* cable.

Sensor

(HEAT 1 OUTPUT)

Wiring should be kept separate

from mains wiring to minimise

functions for remote sensor.

therefore all wiring to the control must be

*The power supply is non-isolated,

mains rated.

noise pick up. Set within Engineers

eg B.M.S.

230V 50Hz 1 Pha

Supply via Isolator

via a 3A fused spur.

Note: Connection to the

burners MUST be made

Volt Free

Circuit

Fan Trip

by others

Indication

Inverter

Unit

Local Relay

Drawing No. : 900287 R4

U V W1 342

+15V DC

Low Voltage

LL NN

230V 3-Phase Supply.

FAN MOTOR

Motor must be wired DELTA

4-Core Armoured or

and fan is 5m (EMC class A building) or

Exhaust

Fan

(fan types B80 / B160 & B300):

MPORTANT

For Inverter panels only

MAXIMUM length of cable between inverter

N.B. if in doubt, do not exceed 5m.

10m (EMC class B building).

Isolator

3 Phase

Screened Cable 1.5mm²

SUPPLY VIA ISOLATOR

230V 1P 22A

ELECTRICAL INPUT

B80

FAN TYPE

S/L2

R/L1

230V 1P 22A

230V 1P 30A

B160

B300

THE LOCAL RELAY UNIT houses an inverter. This

V/T3U/T3 V/T3

three-phase 230V output. The inverter provides a

soft start to the motor, which extends the motor life

converts the 230V single-phase input into a

by minimising the start current.

ESC ENT

Page 16

Figure 4.m. NRV Schematic interconnecting wiring. BH300 three phase fans controlled by SmartCom3 via three phase Local Relay panel. (single zone shown)

Zone A

burners

Supply to inline

Burners

NOTES:

should be connected by 6A mains

REMOTE SWITCH INPUTS

Max length is 100m.

Low voltage switching inputs to be

LIVE

NEUT

SmartCom

Singlezone

enable).

Connect to B0 & B1 for remote ON

normally open (closed circuit to

frost etc).

therefore all wiring to the control must be

*The power supply is non-isolated,

Connect to B0 & B2 for remote

OFF (ie door interlock. remote

(ie BMS time control).

B1 B0 B2 S/R0S/R1

41 40 9 5 1/L 2/N 10

from the control unit, using

Wiring should be kept separate

from mains wiring to minimise

functions for remote sensor.

therefore all wiring to the control must be

placed at a max distance of 100m

REMOTE SENSOR(s) may be

(COMMON)

(NEUTRAL)

(LIVE)

Black Bulb

(REMOTE ON)

screened 6A mains* cable.

Sensor

(REMOTE OFF)

(HEAT 1 OUTPUT)

(FAN CIRCUIT)

mains rated.

*The power supply is non-isolated,

mains rated.

noise pick up. Set within Engineers

eg B.M.S.

230V 50Hz 1 Pha

Supply via Isolator

via a 3A fused spur.

Note: Connection to the

burners MUST be made

Volt Free

Circuit

Fan Trip

Indication

by others

34 2 1

Unit

Local Relay

Drawing No. : 900289 R4

U V W

230V AC

Mains Voltage

L2L3 L1 L1

415V 3-Phase Supply.

FAN MOTOR

Motor must be wired DELTA

4-Core Armoured Cable

Exhaust

Fan

Isolator

3 Phase

415V 3P 25A

ELECTRICAL INPUT

SUPPLY VIA ISOLATOR

BH300

FAN TYPE

Page 17

Figure 4.n. NRV Schematic interconnecting wiring. B80, B160 and B300 three phase fans controlled by SmartCom3 via single phase Inverter panel. Zonal BMS Lockout and VF interface.

Volt

BMS

Volt Free Fan Trip Circuit

Circuit

Volt Free Burner Lockout

Circuit

Volt Free Remote ON

230V VBurner ON Signal

Sensor

Black Bulb

Free

230V 50Hz 1 Pha

Supply via Isolator

Burners

Drawing No. : 900287 R4 LO

Zone A

LIVE

NEUT

SmartCom

Singlezone

230V 3-Phase Supply.

FAN MOTOR

Motor must be wired DELTA

NOTES:

41 40 9 5 1/L 2/N 10

B1 B0 B2S/R0S/R1

(REMOTE OFF)

(COMMON)

(REMOTE ON)

(NEUTRAL)

(LIVE)

(HEAT 1 OUTPUT)

(FAN CIRCUIT)

THE SOFTWARE FOR THE BMS MUST ONLY REQUEST A

Note:

LOCKOUT CONDITION WHEN THE SYSTEM IS

Connection to the

REQUESTING HEAT. IN ADDITION, IT SHOULD ALSO

PROVIDE A 60s DELAY BEFORE INDICATING LOCKOUT.

be made via a

burners MUST

AFTER INITIAL SUPPLY IS CONNECTED TO THE HEATER,

WHEN CALLING FOR THE HEAT VIA THE CONTROL

THIS IS TO ALLOW THE SOLENOID COIL TO OPERATE

3A fused spur.

will receive a false report of the burner status

SYSTEM AND A RE-START ATTEMPT IF NECCESARY

Note: If the point is not complied with the BMS

Inverter

Unit

Local Relay

U V W1 342

+15V DC

Low Voltage

mains rated.

from the control unit, using

screened 6A mains* cable.

functions for remote sensor.

*The power supply is non-isolated,

placed at a max distance of 100m

Wiring should be kept separate

from mains wiring to minimise

therefore all wiring to the control must be

noise pick up. Set within Engineers

REMOTE SENSOR(s) may be

LL NN

Exhaust

Fan

MPORTANT

Isolator

3 Phase

and fan is 5m (EMC class A building) or

(fan types B80 / B160 & B300):

MAXIMUM length of cable between inverter

For Inverter panels only

10m (EMC class B building).

230V 1P 22A

4-Core Armoured or

N.B. if in doubt, do not exceed 5m.

Screened Cable 1.5mm²

SUPPLY VIA ISOLATOR

230V 1P 30A

ELECTRICAL INPUT

B80

B160

B300

FAN TYPE

three-phase 230V output. The inverter provides a

THE LOCAL RELAY UNIT houses an inverter. This

soft start to the motor, which extends the motor life

converts the 230V single-phase input into a

by minimising the start current.

Page 18

Figure 4.p. NRV Schematic interconnecting wiring. B80, B160 and B300 three phase fans controlled by SmartCom3 via Inverter panel. Individual BMS burner Lockout and VF interface.

Volt

Volt Free Fan Trip Circuit

Free

BMS

Circuit Burner #3 Volt Free Burner Lockout

Circuit Burner #2 Volt Free Burner Lockout

Circuit Burner #1 Volt Free Burner Lockout

Circuit Volt Free Remote ON

Drawing No. : 900287 R4 LOM

Zone A

Burners

230V VBurner ON Signal

Sensor

Black Bulb

(REMOTE OFF)

(COMMON)

B1 B0 B2S/R0S/R1

LIVE

NEUT

(REMOTE ON)

(NEUTRAL)

(LIVE)

230V 50Hz 1 Pha

Supply via Isolator

THE SOFTWARE FOR THE BMS MUST ONLY REQUEST A LOCKOUT

CONDITION WHEN THE SYSTEM IS REQUESTING HEAT. IN ADDITION,

LOCKOUT. THIS IS TO ALLOW THE SOLENOID COIL TO OPERATE

IT SHOULD ALSO PROVIDE A 60s DELAY BEFORE INDICATING

AFTER INITIAL SUPPLY IS CONNECTED TO THE HEATER, WHEN

the BMS will receive a false

CALLING FOR THE HEAT VIA THE CONTROL SYSTEM AND A

report of the burner status.

RE-START ATTEMPT IF NECCESARY.

Note: If the point is not complied with

Note:

be made via a

3A fused spur.

burners MUST

Connection to the

(HEAT 1 OUTPUT)

SmartCom

230V 3-Phase Supply.

FAN MOTOR

Exhaust

Singlezone

Motor must be wired DELTA

Fan

(FAN CIRCUIT)

41 40 9 5 1/L 2/N 10

(FAN CIRCUIT)

Inverter

Local Relay

Unit

U V W1 342

+15V DC

Low Voltage

NOTES:

from the control unit, using

screened 6A mains* cable.

placed at a max distance of 100m

from mains wiring to minimise

Wiring should be kept separate

REMOTE SENSOR(s) may be

noise pick up. Set within Engineers

functions for remote sensor.

*The power supply is non-isolated,

3 Phase

mains rated.

therefore all wiring to the control must be

MPORTANT

For Inverter panels only

Isolator

and fan is 5m (EMC class A building) or

(fan types B80 / B160 & B300):

MAXIMUM length of cable between inverter

10m (EMC class B building).

4-Core Armoured or

N.B. if in doubt, do not exceed 5m.

Screened Cable 1.5mm²

LL NN

230V 1P 22A

230V 1P 30A

ELECTRICAL INPUT

SUPPLY VIA ISOLATOR

B80

B160

B300

FAN TYPE

THE LOCAL RELAY UNIT houses an inverter. This

three-phase 230V output. The inverter provides a

soft start to the motor, which extends the motor life

converts the 230V single-phase input into a

by minimising the start current.

Page 19

1.7 Ventilation Requirements

Nor-Ray-Vac heaters are installed as flued appliances in accordance with the relevant national requirements i n the country of installation.

In buildings having an air change rate of less than 0.5 per hour, additional ventilation is required. For detailed information, please see BS6896 section 5.2.2.2.1

Natural Ventilation

Low level ventilation openings with a free area of at least 2cm²/kW shall be provided. See BS6896 section 5.2.2.2.2.1.

1.8 Exhaust and Air Inlet - Options

1.8.1 Horizontal discharge

1.8.2 Vertical discharge

Considerations.

The vacuum fan must be located as shown in the layout drawing.

The vacuum fan must have a bottom horizontal discharge.

The fan should be fitted to the mounting platform which is fixed to the wall or building structure. Alternatively, the fan can be suspended from the roof structure, via drop rods (not supplied) and mounted on base frame. (Anti-vibration mountings are fitted between the fan and the mounting platform/base frame.

For full details of parts and installation, please refer to section 2.9.3

Page 20

1.8.3 Ducted Air Inlet Considerations.

Heat resistant flexible tube is connected to the burner assembly ducted air adaptor and the EVM ducted air adaptor and connected to the air supply duct

The maximum length of 100mm diameter ductwork is 2m.

Ensure that the flexible supply duct does not drape over or touch the reflector.

Figure 5.a. Header Duct Connection

Main header Duct Ø150 for LR12-24 Ø200 for LR32-46

Ensure that the flexible ductwork is installed to allow for expansion of the heating system.

On a header duct, the main air supply header which is feeding the individual branch ducts and burner/end vent supply ducts must have a maximum pressure drop of 0.25 mbar (0.1in wg).

All joints and seams in the air supply system must be made air tight and a bird screen used at the inlet.

For full details refer to section 2.13

Branch Duct Ø100 for LR12-24, Ø150 for LR32-46

Ø100 Duct to burner

Ø100 Duct to EVM

500mm MIN

450mm MIN

(For heater duct

Directly above system)

Figure 5.b.

End Vent Ducted

Air Inlet Connection

Figure 5.c. Burner Ducted Air Inlet Connection

Page 21

1.9 Vacuum fan mounting details (Type ‘B160’ fan illustrated)

A (crs) B C D E (Ø) F G (Ø) H J K L M N P

Fan Size B80 B160 B300 BH300

216 276 286 324 595 595 625 704 305 308 330 352 580 555 575 650 150 152 152 152

50 97 50 50 150 150 150 148 295 318 340 380

80 90 90 110 150 140 140 120 240 240 240 240 309 303 341 404

50 62 157 157 421 463 616 680

R (crs) S (crs) T V X

318 318 318 318 356 356 356 356 204 204 204 204 115 115 115 115

21 36 46 84

Page 22

1.10 Technical Details.

Tables 4a & b Burner Details

No of Injectors

Gas Connection

Burner current

Electrical Voltage/Ph/Hz

½ in BSP Internal thread

0.05 (per burner)

230 volt 1 phase 50Hz

Burner Type 12LR 18LR 24LR 32LR 38LR 46LR

Burner Details

Gas Category II Heat input (Gross) kW 12 18 24 32 38 46 Gas consum rate Nat Gas G20 m³/h 1.14 1.72 2.29 3.05 3.62 4.38 Max Inlet pressure Nat Gas G20 mbar 50

G20 Natural Gas

Min Inlet Pressure Nat Gas G20 mbar 17.5 Hs Nat Gas G20 MJ/m³ 37.78 Hi Nat Gas G20 MJ/m³ 34.02 d Nat Gas G20 0.555 Ws Nat Gas G20 MJ/m³ 50.72 Wi Nat Gas G20 MJ/m³ 45.67 Injector size Nat Gas G20 mm 3.6 4.4 4.9 5.4 5.8 6.3 Injector Part No. L100336 L100544 L100549 L100554 L100558 L100563 Air shutter size Nat Gas G20 mm 13 17 19.5 22.0 24.0 26.5 Air shutter Part No. L100322 L100321 L100320 L100314 L100316 L100318 Gas Category II Heat input (Gross) kW 12 18 24 32 38 46 Gas consum rate Nat Gas G25 m³/h 1.33 1.99 2.66 3.55 4.21 5.10 Max Inlet pressure Nat Gas G25 mbar 50

G25 Natural Gas

Min Inlet Pressure Nat Gas G25 mbar 20 Hs Nat Gas G25 MJ/m³ 32.49 Hi Nat Gas G25 MJ/m³ 29.25 d Nat Gas G25 0.612 Ws Nat Gas G25 MJ/m³ 41.52 Wi Nat Gas G25 MJ/m³ 37.38 Injector size Nat Gas G25 mm 3.7 4.6 5.2 5.8 6.3 6.9 Injector Part No. L100537 L100546 L100552 L100558 L100563 L100569 Air shutter size Nat Gas G25 mm 13 17 19.5 22.0 24.0 26.5 Air shutter Part No. L100322 L100321 L100320 L100314 L100316 L100318

Page 23

Tables 4c & d Burner Details

Burner Type 12LR 18LR 24LR 32LR 38LR 46LR

Burner Details

Gas Category III Heat input (Gross) kW 12 18 24 32 38 46 Gas consum rate Butane G30 m³/h 0.34 0.52 0.69 0.92 1.09 1.32 Max Inlet pressure Butane G30 mbar 35

G30 Butane Gas

Min Inlet Pressure Butane G30 mbar 20 Hs Butane G30 MJ/m³ 125.81 Hi Butane G30 MJ/m³ 116.09 d Butane G30 2.075 Ws Butane G30 MJ/m³ 87.33 Wi Butane G30 MJ/m³ 80.58 Injector size Butane G30 mm 2.6 3.2 3.7 4.2 4.6 5.1 Injector Part No. L100526 L100532 L100537 L100542 L100546 L100551 Air shutter size Butane G30 mm 13 17 19.5 22.0 24.0 26.5 Air shutter Part No. L100322 L100321 L100320 L100314 L100316 L100318 Gas Category III Heat input (Gross) kW 12 18 24 32 38 46 Gas consum rate Propane G31 m³/h 0.45 0.68 0.90 1.21 1.43 1.73 Max Inlet pressure Propane G31 mbar 57.5

G31 Propane Gas

Min Inlet Pressure Propane G31 mbar 25 Hs Propane G31 MJ/m³ 95.65 Hi Propane G31 MJ/m³ 88.00 d Propane G31 1.55 Ws Propane G31 MJ/m³ 76.84 Wi Propane G31 MJ/m³ 70.69 Injector size Propane G31 mm 2.9 3.5 4.0 4.4 4.8 5.2 Injector Part No. L100529 L100535 L100540 L100544 L100548 L100552 Air shutter size Propane G31 mm 13 17 19.5 22.0 24.0 26.5 Air shutter Part No. L100322 L100321 L100320 L100314 L100316 L100318

Hs = Gross CV Hi = Net CV Ws = Wobble number on gross CV Wi = Wobble number on net CV d = specific density Reference gas conditions = dry, 15ºC 1013 mbar

Page 24

Table 5. Heater Details

Burner Type

Min distance between burners m 5.2 7.4 9.4 14 18 23 Max distance between burners m 7.2 10.2 13.1 18 23 27

Min distance between burner and fitting

Max tube temp °C 450 480 Min mounting height m 3.0 3.6 4.0 4.7 5.3 6.0 Max burners per branch 5 4 3 3 3 3

m 3.6 3.6 5.0 6.0 7.0 8.0

Table 6. End Vent Module (EVM)

Burner Type

End vent setting (hot)

- Multi burner systems End vent setting (hot)

- SINGLE End Vent burners only End vent setting (hot)

- THREE burners in a branch End Vent orifice diameter mm 14.5 16 24 27 32 n/a

mbar

mbar n/a n/a n/a 7.5 8.25 9.25

mbar n/a n/a n/a n/a n/a 5.6

12LR 18LR 24LR 32LR 38LR 46LR

6.25 6.25 6.25 6.25 6.25 6.25

End Vent orifice Part No. L104102 L104101 L104100 L104093 L104092 n/a

Table 7. Burner Dip-switch position

(see section 3.3.1.8)

Burner Number

(within each radiant branch lowest number closest to fan)

To set dip-switch slide the white switch toward the numbers (1-4)

Table 8. Noise Data

Burner Type

Noise level @ 3m below In-Line BURNER

Noise level @ 3m below

EVM Burner

1 1 1 1 1 1 2 - 2 2 2 1 3 - - 3 3 2 4 - - - 4 3 5 - - - - 4

db(A) 46 47 47 48 50 51

NR±2 40 41 41 42 44 45

db(A) 46 48 48 52 55 58

NR±2 40 42 42 46 49 52

1 2 3 4 5

12LR 18LR 24LR 32LR 38LR 46LR

Number (qty) of burners in-line

Noise level @ 3m below

EVM with silencer

Noise level @ 3m below

EVM Burner with Ducted Air

db(A) 44 45 45 48 51 53

NR±2 38 39 39 42 45 47

db(A) tba tba tba tba tba tba

NR±2 tba tba tba tba tba tba

Page 25

Table 9. Fan Details

Fan Size

Fan part number Motor (TEE) Power kW 1.1 1.5 2.2 4.0 Supply to Fan V/Hz/P 230~50/3 230~50/3 230~50/3 400~50/3 Run Current A 4.38 5.6 8.48 7.2 Start Current A n/a n/a n/a 54.0 Speed RPM 2850 2860 2480 2880 Wired Flow rate @ 20°C m³/h 368 736 1380 1380 Flow rate @ 150°C m³/h 259 519 972 972 Pressure mbar 29 29 29 42 Max Operating Temp. °C 200 200 200 200 Weight kg 45 52 58 75

QS 80M2B H QS 90S2A-40H QS 90L2A H QS 112M2A H

Table 10. Local Relay Unit

Fan Size B80 B160 B300 BH300

B80 B160 B300 BH300

201760 201761 201732 201763

∆ ∆ ∆

LRU part number Inverter type kW 1.5 1.5 2.2 n/a Supply to LRU V/Hz/P 230~50/1 230~50/1 230~50/1 400~50/3 Line Current A 14.8 14.8 20.8 n/a Motor Current A 4.2 5.6 7.8 7.2 Fuse Rating A 22 22 30 n/a Acceleration Time s 25 25 25 n/a Deceleration Time s 25 25 25 n/a

Table 11. System Weights

LR Burner kg 8.3 Radiant branch* kg/m 8.3 Radiant branch + Slimline grille* kg/m 10.9 Radiant branch + Protective guard* kg/m 10.0 4” Mild steel tail pipe kg/m 5.5 4” Aluminum tail pipe kg/m 0.9

Burner Type

900274 900088 900089 900282

12LR 18LR 24LR 32LR 38LR 46LR

6” Mild steel tail pipe kg/m 10.6 6” Aluminium tail pipe kg/m 1.3 Max / susp point @ EV position kg 24.2

* without burners or ducted air systems

Page 26

2. Assembly Instructions.

PLEASE READ this section prior to

assembly to familiarise yourself with the components and tools you require at the various stages of assembly. Carefully open the packaging and check the contents against the parts and check list.

The manufacturer reserves the right to alter specifications without prior notice.

2.1 Tools Required.

The following tools and equipment are advisable to complete the tasks laid out in this manual.

Trestles

Wrench With Extension

Leather Faced Gloves

13mm Socket

Please ensure that all packaging is disposed of in a safe environmentally

friendly way.

For your own safety we recommend the

use of safety boots and leather faced gloves when handling sharp or heavy items. The use of protective eye wear is also recommended.

Suitable alternative tools may be used.

Pozidrive Screwdriver

Tape Measure

10mm,

12mm & 13mm Spanners

4 & 5mm Allen Keys

Saw

2.2 Assembly Notes.

Please read these assembly notes in

conjunction with the correct assembly drawings (Sections 2.2.1 to 2.21.1)

The system is assembled at high level suspended by chains from first fixings to the roof structure. (First fixings by others)

2.2.1 Radiant Tubes

Note: on assembly, tube seams to be facing upwards.

All radiant tubes are 101mm (4”) O/D, ERW

steel to BS 6323:Part 5: are factory pre-painted and supplied in 5.2m

lengths. These may need to be cut depending on the system drawing design.

Pop Riveter & 3/16” Rivets

Silicone Sealant & Gun

Burner Combustion Chamber

Combustion chambers are

2.6m in length and increase in

diameter to 127mm (5”) around the

burner turret.

All tubing, combustion chambers, dampers and

tube fittings are connected by ‘wrap-around’ stainless steel couplers which clamp by means of two high tensile stainless steel set pins. (See

section 2.2.2)

Page 27

2.2.2 Couplers

The Nor-Ray-Vac Tube Coupler is a screw tightening, self aligning - positive located tubular coupler. Manufactured in a non–corrosive stainless steel it is available in both 100mm (4”) and 150mm (6”).

Two high tensile stainless steel set pins tighten to clamp the coupler onto the tube whilst a rivet provides a centralised permanent stop to give the joint equidistance.

The following procedure explains the correct method of assembly:

Before assembly, carefully loosen the two screws. Position the coupler onto the first tube ensuring that the bars are positioned uppermost.

Slide the second tube into the coupler ensuring that the rivet stop has butted up to the tube end.

Using the 6mm allen key, tighten the second pin. DO NOT OVERTIGHTEN.

Slide the coupler over the tube ensuring that the rivet stop has butted up to the tube end.

Using a 6mm allen key, tighten the relevant pin. DO NOT OVERTIGHTEN.

Moving between the two set pins, tighten both ensuring that equal pressure is applied to each set pin in turn.

If all steps have been followed correctly, the coupler should have aligned itself parallel to the two tubes and a slight indentation can be observed. Using the 6mm allen key, finally tighten each screw by a further quarter turn. If a power tool is used, use a torque limit setting of

6.6 lbf/ft (0.91kgf/m) must be achieved.

Page 28

2.2.3 Reflectors

The radiant tube sections of the system are fitted with reflectors made of either stainless steel or aludip to direct infra-red rays downwards.

The reflectors have a unique design profile to maximise the reflected radiant heat, minimise convective loss, and maximise on rigidity.

The reflectors are overlapped and held in position by the reflector bracket assembly.

2.2.3.3 Corner Reflectors

Used where radiant tubes are joined with a 90° bend. The corner reflector comes in two pieces and is assembled on-site.

Corner Reflector

There are two styles of reflectors:

2.2.3.1 Standard Reflectors

These 2.4m long reflectors are positioned above the tube to radiate the heat downwards and are fixed to the radiant tube via a reflector bracket (see section 2.5). The combustion chamber reflector has a rectangular hole and slot, pre cut to allow for burner combustion chamber and support lug fitting.

2.2.3.4 Tee piece Reflectors

Used where a radiant tube connects to another at right angles. The reflector is a special short section with a central tube cut out.

Tee section

Combustion Chamber Reflector

2.2.3.2 Perimeter Reflectors

Perimeter reflectors are used when the radiant tube is mounted at the perimeter of the building. They have the same profile as standard reflectors but extended one side to direct the radiant heat away from the wall.

The perimeter combustion chamber reflectors have a cut-out for the combustion chamber turret and suspension lug at both ends so that the one reflector can be used for either left or right hand perimeter systems.

2.2.4 Brackets

There are two styles of brackets:

2.2.4.1 Suspension brackets.

Suspension brackets are made from a one piece construction and are formed to support the tube and reflector alike. The wrap around ends are aligned to hold a turnbuckle eyelet in the correct hanging position.

Note: when overlapping the perimeter combustion chamber reflector, extra overlap is required to cover the pre-cut holes and slot.

Standard Suspension Bracket

Page 29

A perimeter suspension bracket is available which has the same profile as the standard

brackets but extended one side to accommodate the perimeter reflector.

Perimeter Reflector Support Bracket

2.2.4.2.1 Attachment of reflector

bracket. Primeter Suspension Bracket

2.2.4.2 Reflector Support Bracket

Reflector Support Brackets are a two piece construction. The first half is formed to seat on top of the radiant tube and supports the reflector sides in position. The second part clamps around the bottom half of the tube and is fixed in position via a fastener.

Fit the reflector bracket (B) around the

tube and tighten the set pin (D) to clamp the

central clip (C) to the tube.

The set pins (A) positioned at both edges of the

bracket (B) are used to provide either a fixed

joint or a sliding joint.

Fully tighten these screws for fixed joints.

‘Fixed Joint’ detail.

Standard Reflector Support Bracket

Leave a minimum 3mm gap clearance between

The reflector support bracket has two functions depending on the position of the fixing screws.

1. To fix the reflector into position.

2. To allow the reflector to slide within the bracket for thermal expansion.

A perimeter reflector support bracket is available which has the same profile as the standard

brackets but extended one side to accommodate the perimeter reflector.

reflector and screws for a sliding joint.

‘Sliding Joint’ detail.

The reflector overlap after each burner must be a ‘sliding joint’, to allow for thermal expansion.

min 3mm GAP

Page 30

The next downstream reflector overlap must be a ‘fixed joint’.

This pattern of alternate sliding and fixed joints will continue up to the next in line burner or damper assembly.

A reflector support bracket must be positioned at the end vent and at the damper end of each radiant branch, plus either side of a reflector corner and reflector tee section.

These units must be ‘fixed joints’.

2.2.5 Burner

2.2.5.1 LR Burner Unit

Each burner will consist of:

The ignition and flame sensing electrode assembly is mounted to the casting flange of the burner face.

2.2.6 End Vent Module (EVM)

At the start of each radiant branch an end vent module is connected to the rear of the first combustion chamber. The end vent module externally maintains the lines of the reflector profile.

A burner control housing (BCH) of chassis style with detachable pivoting lid. All control wiring to the burner head is within the BCH, which also contains a combination gas valve comprising of 2 class 2 solenoid valves, dedicated zero governor and filter, a full sequence controller and cassette air filter for primary air supply to the burner. Externally on the BCH, neon lights indicate mains on and burner on modes.

The air and gas are pre-mixed to stoichiometric proportions within the burner head assembly, prior to being admitte d to the point of combustion.

Ignition is by an electric arc forward of the face of the burner head on to the main frame.

To comply with European standards that state air flow must be proven in each radiant branch, the end vent burner incorporates an air pressure switch. The end vent module incorporates the flow sensing pipework carrier air orifice plate and optional silencer box to reduce noise levels.

2.2.7 Vacuum fans

A low noise robust steel plate fabricated centrifugal fan coated with heat and corrosion resistant paint, capable of a static pressure of either 29 mbar or 45 mbar at 20°C and directly coupled to a totally enclosed motor to be fitted at the end of the tube system.

The fan exhausts the products of combustion

LR Burner

from the system discharging through an outlet flue pipe to atmosphere external to the building.

2.2.5.2 Burner Head

A burner head assembly of lightweight cast aluminium construction, a ceramic style burner head insert, maintained in position by the flame

The maximum operating temperature is 200°C.

The fan motor is IP55

rated for external use. retention grid. The casting assembly also accommodates the gas jet, air shutter and mixing chamber.

LR Burner head

End Vent Module

Exhaust Fan

Page 31

2.3 Installation of End Vent Section.

connect the speedlink (C) to the turnbuckle (D).

speedlink (C) through the eye of the suspension lug (B), and then

2.3.3 Suspend the end vent combustion chamber (A) by locating the

vent burner combustion chamber (A).

2.3.2 The first support is positioned at the suspension lug (B) on the end

chamber turret and lug (B)

2.3.1 locate the cut out of the combustion chamber reflector (N) over the combustion

max load per support of 24kg.

approximately 2.8m apart, This gives a

2.3.4 Subsequent supports (E) are placed

2.3.5 Except for the combustion chamber

suspension lug (B), suspension support

brackets (E) are installed to support the

tube section which is then covered with

reflectors.

the end vent towards the fan.

A. Combustion Chamber - L101020-SUB; B. Suspension Lug; C. Speedlink - 6524; D. Turnbuckle -

C766300-SUB; E. Suspension Hanger - C110500-SUB (perimeter - C110501-SUB); F. Radiant Tube

2.3.6 Connect a length of radiant tube (F) to the end vent combustion

chamber (A) by use of couplings (G), ensuring it is supported by the suspension

support brackets (E).

NOTES: 1. The radiant tube should be installed with the seam weld facing upwards.

2. Ensure the radiant tube is installed in the horizontal or with a slight fall away from

Ø100 - 1040; G. Tube Coupler - C112110 (Ø100); N. Combustion Chamber Reflector - L105050.

Page 32

or elbow (H) fitting.

be located at a maximum

distance of 2m from a tee

2.3.12 A support (E) must

2.3.10 Connect a length of radiant tube (F) to the

end vent combustion chamber (A) by use of couplings

(G), ensuring it is supported by the suspension support

brackets (E).

weld facing upwards.

NOTES: 1. The radiant tube should be installed with the seam

with a slight fall away from the end vent towards the fan.

2. Ensure the radiant tube is installed in the horizontal or

2.3.11 Subsequent supports (E) are placed approximately 2.8m apart. This

gives a max load per support of 24kg.

A. Combustion Chamber - L101020-SUB; B. Suspension Lug; C. Speedlink - 65 24;

D. Turnbuckle - C766300-SUB; E. Suspension Hanger - C110500-SUB (perimeter -

C110501-SUB); F. Radiant Tube Ø100 - 1040; G. Tube Coupler - C112110 (Ø100),

H. 90° Bend - C112108 (black Ø100); N. Combustion Chamber Reflector -

L105050.

2.3.8 Suspend the in-line combustion

chamber (A) by locating the

speedlink (C) through the

eye of the suspension lug

2.3.7 locate the cut out of the in-line

combustion chamber reflector (N) over

the in-line combustion chamber turret

and lug.

Installation of Radiant Tube (In-line Section)

(B), and then connect

the speedlink (C) to the

turnbuckle (D).

2.3.9 Except for the in-line

combustion chamber suspension

lug (B), suspension support brackets (E)

are installed to support the tube section

which is then covered with reflectors.

Page 33

2.4 Installation of Radiant tube to Tail Pipe

2.4.3 Connect

the radiant tube

section to the tail pipe

section (L) by use of a tube

increaser (J) and couplings (G), as

per the layout drawing.

2.4.2 Dampers (I) must be

located as indicated in the layout

drawing. The adjustment lever

must be positioned to one side

to allow clear access for

setting.

Note: The final 12m of tail

pipe prior to the vacuum fan is

2.4.1 Tail pipe hangers (K) slung from turnbuckl es

(D) and Speedlinks (C) are installed to hang

the manifold and tail pipe section

which will be without

aluminium (M). All tube couplers on

this section ONLY must be sealed with a bead of

silicone sealant on each side of the coupler.

NO SEALANT ON ANY BLACK TUBE!!

Note: Ensure the tail pipe section has the correct fall

reflectors.

(25mm in every 6m towards the fan).

C. Speedlink - 6524; D. Turnbuckle - C766300-SUB; E. Suspension Hanger - C110500-SUB; G. Tube Coupler - C11 2110 (Ø100),

C112120 (Ø150); H. 90° Bend - C112108 (black Ø100), C112109 (black Ø150), L101554 (Alu m Ø150); I. Damper - C110241-SUB;

J. Increaser - C112117; K. Ø150 Tail Pipe Hanger - C112015; L. Ø150 Black Tail Pipe - C112126; M. Ø150 Alum Tail Pipe - 7230-3.

Page 34

2.5 Installation of Main Reflectors

2.5.4 The third reflector bracket (P3) is installed 100mm

from the end of the first plain reflector (O1). 2.5.5 Slide the second plain reflector (O2) through the

second downstream suspension support bracket (E2), then

over the first plain reflector (O1) and into the third reflector

bracket (P3). Ensure that the reflector overlap is a

complete.

until the radiant branch is

brackets where required

additional reflectors / support

2.5.6 Continue this sequence, installing

minimum of 225mm.

2.5.3 Slide the first plain reflector (O1) through the first

downstream suspension support bracket (E1), then under

the combustion chamber reflector (N) and into the second

reflector bracket (P2). Ensure that the reflector overlap is a

minimum of 225mm.

2.5.1 Install the first reflector bracket

(P1) behind the turret of the combustion

chamber (A). 2.5.2 Install the second reflector bracket (P2)

100mm from the other end of the combustion

chamber reflector (N).

A. Combustion Chamber - L101020-SUB; E. Suspension Hanger - C110500-SUB; O. Plain Reflector - L1050 24;

P. Reflector Support Bracket - L201008-SUB;

Page 35

2.6 Installation of Corner Reflectors

2.6.1 The corner section must first be assembled by overlapping the right hand reflector (Q1) over the

tabbed left hand reflector (Q2) and secured using a No. 8 self tapping screws into a capture nut placed on

the flange of the reflector (Q2). nb Ensure that the two reflector overlaps are 225mm.

plain reflector (O1) will need to be used by cutting down a standard length. NOTE: this is the only

2.6.2 Position a reflector support bracket (P) at the centre of each reflector overlap. 2.6.3 If a bend connects directly with the rear of an in-line combustion chamber, a short section of

situation where a reflector is cut short, in all other situations increase of the overlap will be necessary.

A. Combustion Chamber - L101020-SUB; E. Suspension Hanger - C110500-S UB; O. Plain Reflector - L105024; P. Reflector Support Bracket - L201008-S UB;

Q. Corner Reflector Assembly - L105009-SUB

Page 36

2.7 Installation of Tee Reflectors

225mm

n.b. Ensure that the reflector

overlaps are a minimum of

225mm.

2.7.1 Position the reflector with side

cut-out over the ends of the two plain

reflectors. 2.7.2 Position a reflector support

bracket (P) at the centre of each

reflector overlap and 100mm

from end of last plain reflector

in radiant branch. 2.7.3 At the entry to the tee

section, the plain reflector (O)

MUST be fitted with a reflector

end cap (S).

C. Speedlink - 6524; D. Turnbuckle - C766300-SUB; E. Suspension Hanger - C110500-SUB; G. T ube Coupler - C112110 (Ø100), C1 12120 (Ø150); I. Damper - C1102 41-SUB;

O. Plain Reflector - L105024; P. Reflector Support Bracket - L201008-SUB; R. Reflector with Side cut out - L105026; S. End Cap - L105043;

Page 37

2.8 Final Fixtures and Adjustment

Thus, the overlap of the perimeter combustion chamber reflector with the

second perimeter reflector must be such that the cut-outs are adequately

covered ie. 1000mm overlap.

systems.

2.8.1 General. Ensure all reflector overlaps are a minimum of 225mm and that

there is a reflector support bracket positioned in the centre of the overlap. 2.8.2 End Caps. At the end of each reflected radiant branch the last reflector

must have an end cap (S) fitted. 2.8.2.1 Using the end cap (S) as a template mark the positions of the two fixing

holes onto the last reflector. Drill two 5mm diameter holes through the positions

marked. 2.8.2.2 Position the end cap (S) under the last reflector and secure using the two

M4 set-screws provided. 2.8.3 Perimeter reflectors (Not shown) Perimeter reflectors are used when the

or right hand perimeter

can be used for either left

ends so that the one reflector

turret and suspension lug at both

a cut-out for the combustion chamber

perimeter combustion chamber reflectors have

the perimeter combustion chamber reflectors. The

procedure is the same as above, with the exception of

reflector bracket assemblies are provided and the assembly

Special perimeter suspension support brackets and perimeter

wall.

L. Ø150 Mild Steel Tail Pipe - C112126;

P. Reflector Support Bracket - L201008-SUB; S. End Cap - L105043;

radiant tube is mounted at the perimeter of the building. They are standard 2.4m

long reflectors but with one side extended to direct the radiant heat away from the

Page 38

2.9 Installation of Fan Exhaust System

using a turnbuckle (D) which is connected to the eye

bolt by a speedlink (C).

2.9.1.5 The condensate trap assembly (V) is connected

to the 150mm diameter fan inlet connection via coupler

(G).

2.9.1 Fan exhaust duct for vertical discharge

2.9.1.1 In vertical discharge, a tee piece (W) must be fitted in the

exhaust ducting with a connection to drain.

Flue couplers (G) are used to connect all exhaust flue fittings. All ducting must be sealed using silicone sealant to avoid condensate

leaking to the outside of the ductwork. Ensure that an adequate weatherproof seal such as a ’dektite’ is

made where the duct passes through the roof. The flue terminal (Zb) is fitted by first applying silicone sealant around

the connecting tube ends and then inserting the swaged end of the

flue terminal into the 150mm diameter flue duct. The joint is secured

by drilling through the tube and connector with 3 pop rivets at 12, 4

and 8 o’clock position. 3.5 mm (3/16 in) diameter pop rivets are

recommended. (Not supplied by AmbiRad).

2.9.1.3 The system aluminium tail pipe (M) is connected via an ex-

pansion joint (T) to the 150 mm condensate trap assembly (V) and

secured by jubilee clips (U) at each end. A gap of approximately 150mm must be maintained between the

condensate trap assembly (V) and the tail pipe (M).

2.9.1.4 The condensate trap assembly (V) must be supported

C. Speedlink - 6524; D. Turnbuckle - C766300-SUB;

E. Suspension Hanger - C110500-SUB; G. Tube

Coupler - C112120 (Ø150); M. Ø150 Alum Tail Pipe -

7230-3; T. Expansion Joint - 7532; U. Jubilee Clip Ø150

- 7542; V. Condensate Trap Assembly - L101527-SUB;

W. Tee Piece Ø150 - M201024; Xa. Fan Wall Mounting

Platform - L103060; Xb. (alternate) Fan Base Frame;

Y. Fan - refer table.9; Za. Ø150 Flue Pipe (1m lengths)

- A791050; Zb. Flue Terminal - L101580-SUB

2.9.1.2 The vacuum fan (Y) must be located as

shown in the layout drawing and must have a bottom

horizontal discharge. The fan can be fitted to the mounting

platform (Xa) which is fixed to the wall or

building structure. Alternatively, the fan

can be suspended

from the roof

structure, via drop

rods (not supplied)

and mounted on

base frame (Xb).

Page 39

Installation of Fan Exhaust System cont.

connect all exhaust duct fittings.

from the fan to avoid condensate running back

into the fan. Flue couplers (G) are used to

sealant to avoid condensate leaking to the

ends and then inserting the swaged end of the

flue terminal into the 150mm diameter flue duct.

The joint is secured by drilling through the tube and

connector with 3 pop rivets at 12, 4 and 8 o’clock

position. 3.5 mm (3/16 in) diameter pop rivets are

recommended. (Not supplied by AmbiRad).

assembly (V) and the tail pipe (M).

maintained between the condensate trap

A gap of approximately 150mm must be

jubilee clips (U) at each end.

condensate trap assembly (V) and secured by

nected via an expansion joint (T) to the 150 mm

2.9.2.3 The system aluminium tail pipe (M) is con-

The condensate trap assembly (V) must be

The flue terminal (Zb) is fitted by first applying

silicone sealant around the connecting tube

building wall.

sleeve (a - not supplied by AmbiRad) must be

fitted between the exhaust flue duct and the

outside of the ductwork. A non-combustible

All flue ducting must be sealed using silicone

2.9.2 Fan exhaust duct for horizontal discharge

2.9.2.1 The exhaust flue duct (Za) must incline downwards away

supported using a turnbuckle (D) which is connected to the

eye bolt by a speedlink (C). The condensate trap assembly (V) is connected to the

150mm diameter fan inlet connection via coupler (G).

2.9.2.2 The vacuum fan (Y) must be located as

shown in the layout drawing and must

have a bottom horizontal discharge. The fan can be fitted to the

mounting platform (Xa) which is

fixed to the wall or building

structure. Alternatively, the

fan can be suspended

from the roof structure,

via drop rods (not

supplied) and mounted

on base frame (Xb).

C. Speedlink - 6524; D. Turnbuckle - C766300-SUB; E. Suspension Hange r - C110500-S UB;

G. Tube Coupler - C112120 (Ø150); M. Ø150 Alum Tail Pipe - 7230-3; T. Expansion J oint -

7532; U. Jubilee Clip Ø150 - 7542; V. Condensate Trap Assembly - L101527-SUB;

Xa. Fan Wall Mounting Platform - L103060; Xb. (alternate) Fan Base Frame; Y. Fan - refer

table.9; Za. Ø150 Flue Pipe (1m lengths) - A791050; Zb. Flue Terminal - L101580-SUB

Page 40

Installation of Fan Exhaust System cont.

2.9.3.1 The vacuum fan (Y) must be located as shown in the layout drawing and must have a bottom

2.9.3 Fan Mounting

horizontal discharge.

structure. Mounting holes are pre drilled on the vertical legs of the platform.

The fan should be fitted to a mounting platform (X) which is fixed to the wall or building

Locate the mounting stool of the fan into position on the platform (Xa). Ensure

anti-vibration mountings are used and secure in position.

Anti-vibration mountings are supplied as a kit of parts (X1 - X5).

2.9.3.2 Alternatively, the fan can be suspended

from a roof structure, via drop (not supplied)

and mounted on base frame (Xb). Locate the mounting stool of the fan

into position on the frame (Xb). Ensure anti-vibration mountings

are used and secure in

position. X5 not used with

base frame.

Xa. Fan Wall Mounting Platform - L103060; Xb. (alternate) Fan Base Frame;

X1-5 Anti-vibration Mount Kit - L103045-SUB; Y. Fan - refer table.9;

Page 41

Installation of Fan Exhaust System cont.

during commissioning, is adjusted by

rotating handle (V5) then locking with grub

screw.

Damper to control the vacuum of the system

If the drainage pipe has a run externally, it is recommended that the pipe

is insulated to protect against frost.

avoid freezing.

Any external pipework should be kept to a minimum to

Any internal pipework should be of a diameter stated.

pipe to a drain might be subject to local building controls.

It should be noted that the connection of a condensate

rainwater system or a purpose-made soakway.

Alternatively, the condensate can be discharged into the

internally to a soil and vent stack or a waste pipe.

Preferably the condensate pipe should run and terminate

See note*

2.9.4 Condensate Trap Assembly

The condensate trap assembly (V) is connected to the 150mm diameter fan

inlet connection via a coupler. Ensure that a 1½ in (38 mm) drain tube assembly is fitted to the connection

(V1) and to the non-return valve

(V3) via bends (V2). Ensure that the non-return valve

(V3 - supplied) is fitted with the

flow indication arrow pointing

AWAY from the trap, in the

V. Condensate Trap Assembly - L101527-SUB; V1 - Tube Connector; V2. Drain Tube; V3. Non-return Valve; V4. Drain Tube; V5. Damper Handle

HORIZONTAL position and at a

vertical distance of 670mm* for BH

type fans or 520mm* for B type

fans, below the condensate trap assembly. The condensate drainage pipe (V4 - not

supplied) should be run in a standard drain

pipe material, e.g. polyvinyl chloride (PVC),

unplasticized polyvinyl chloride (PVC-U),

ancrylonitrile-butadiene-styrene (ABS),

polypropylene polyproene (PP) or cross-linked

polyviynyl chloride (PVC-C).

Copper or copper based alloy shall not be used for

condensate drains. See BS 6896.

The drain tube must be resistant against the action

of flue gas condensate and suitable for operation

up to a maximum temperature of 50°C. Ensure that the drain tube is adequately supported. All connecting drainage pipework should have a fall

of at least 2.5° to the horizontal or approximately 50mm per metre of pipe

run.

Page 42

2.10 Full Breakdown of Typical System

F. Radiant Tube Ø100 - 1040; G. Tube Coupler - C112110 (Ø100), C112120 (Ø150); H. 90° Bend - C112108 (black Ø100), C112109 (black Ø150),

L101554 (Alum Ø150); I. Damper - C110241-SUB; J. Increaser - C112117; K. Ø150 Tail Pipe Hanger - C112015; L. Ø150 Black Tail Pipe - C112126;

M. Ø150 Alum Tail Pipe - 7230-3; T. Expansion Joint - 7532; U. Jubilee Clip Ø150 - 7542; V. Condensate Trap Assembly - L1015 27-SUB; W. Tee Piece Ø150 -

A. Combustion Chamber - L101020-SUB; B. Suspension Lug; C. Speedlink - 6524; D. Turnbuckle - C766300-SUB; E. Suspension Hanger - C110500-SUB;

M201024; X. Fan Mounting Platform - L103060; Y. Fan - refer table.9; Za. Ø150 Flue Pipe (1m lengths) - A791050; Zb. Flue Terminal - L101580-SUB

Page 43

In-line Burner

2.11 Installation of End Vent and In Line Burners

2.11.3 Position heat shield (AD) on top of gasket (AC) in line with all four

fixing holes of gasket and turret. 2.11.4 Fit each burner through heat shield (AD), gasket (AC) and turret.

Square burner in line with all four fixing holes of gasket and turret.

2.11.5 Secure the burner through the heat shield (AD) and gasket (AC) to

the turret using the four M6 bolts (AE) and washers (AF) provided.

2.11.6 Repeat for all other end

vent and inline burners

End Vent Burner

2.11.1 Each burner is marked with its rated heat input, “EV” denotes end

vent burner (AA), “IL” denotes inline burner (AB). The correct burner

MUST be located as indicated on the site layout drawing. If the difference between the two types is still unclear, the end vent

burner has a pressure switch fitted inside and has two air pipe connectors

located in the bottom right hand corner when looking at the rear of the

AA. End Vent Burner; AB. IL Burner; AC. Burner Gasket - L102032; AD. Burner Heat Shield - 200195; AE. 6mm Set Pin - 5429-1; AF. 6mm Washer - 5425

unit. 2.11.2 Position gasket (AC) on combustion chamber turret (A), in line

with all four fixing holes.

Page 44

2.12 Installation of End Vent Module

2.12.3 Ensure combustion chamber tube end butts positively against the

orifice plate.

Secure using the M8 set pin (AH). 2.12.4 With the EVM (AG) in position on the end of the combustion

chamber: a attach the ‘U’ shaped bundy piece (AJ) to the compression fitting

labelled ‘1’ b attach the ‘L’ shaped bundy piece (AK) to the compression fitting

labelled ‘2’, positioned at the rear of the end vent burner (AA).

Ensure fittings are tightened securely.

2.12.1 An end vent module or ‘EVM’ (AG) is positioned at each end vent

burner position. Each end vent module must be fitted with the correct end vent orifice

plate to suit the end vent burner. An orifice or orifice plate attached inside the EVM support spinning is

located on the air entry point of the EVM.

2.12.2 Slide the EVM support spinning over the end vent combustion

chamber tube.

AA. End Vent Burner; AG. End Vent Module; AH. M8 Set Pin - 5447; AJ. Air Tube 1 - L104053; AK. Air Tube 2 - L104054; 1. Compression fitting # 1; 2. Compression Fitting # 2

Page 45

2.13 Installation of Ducted Air Adaptors

AV *

place inside the housing lid (A) via

The primary air filter (AM) will remain in

2.13.2 Fitting ducted air adaptor to end vent module

The ducted air adaptor (AP) is fitted to the air inlet position of the EVM.

To achieve this, the EVM has to be taken apart. Remove the EVM.

the same screws.

2.13.2.1Unscrew the fasteners (AS) securing the EVM outer plate (AQ)

and remove. 2.13.2.2 Position ducted air adaptor against inlet plate and secure using

four M5 set screws (AT) washers and Nuts (AU) provided.

2.13.2.3 Reposition assembled plate onto the EVM inner plate (AR) and

affix using screws (AS)

* Optional 90° elbow (AV) can be fitted to allow individual orientation.

2.13.1 Fitting ducted air adaptor to burner assembly The ducted air adaptor (AL) is fitted over the air inlet position of the

burner housing lid using two M5x30 set-screws (AN).

Ducted Air Lid

AL. Burner Ducted Air Adaptor - L104115; AM. Filter - L102013; AN. M5x30 Set screw; AP. EVM Ducted Air Adaptor - L104122-SUB; AQ. EVM Outer Plate;

AR. EVM Inner Plate; AS. EVM Fastener; AT. M5 Set Pin - 5369; AU. M5 Nut - 5350; AV. 90° Elbow - 7075-2

Page 46

2.14 Installation of Ball Guard System

2.14.2 Blanking Shields

It may be necessary to prevent heat

being directly emitted from certain points

along the radiated tube. Blanking plates

are available for use with ballguards in

400mm sections, which prohibit this.

nb. Reflectors removed for clarity

2.14.2.1 Place the blanking plate

(BG) inside the ball guard (BA) to

cover the area concerned.

Align two retaining plates

(BD) on the underside of the

guard. Fasten together using

M8x25 pins (BH), M8 nuts

(BE) and washers (BF) prior

to fixing the ball guard as

above.

The Nor-Ray-Vac ballguard system consists of standard 2.44m long modules which are supported from the underside of

the radiant tube. The ballguard sections are fitted in tandem along the system. Perimeter ballguards are installed in the

same manor. 2.14.1 Installation 2.14.1.1 Starting at each system end vent, position the ‘U’ bolts (BB) around the radiant tube, through the clamp bridge

(BC) and secure using with M8 nuts (BE).

Ensure that the distance between the ‘U’ bolts is approximately 1100mm.

The ‘U’ bolt assemblies should be positioned perfectly square to ensure that the

ballguard module lies horizontal when fitted. 2.14.1.2 A retaining plate (BD) is positioned on the underside of

the ballguard (BA) at each ‘U’ bolt assembly position and

secured using M8 nuts (BE) and washers (BF). 2.14.1.3 It is necessary to cut the edge of the

ballguard section (BA) at the interface

with the suspension support bracket.

If necessary a standard 2.44m

long ballguard can be

shortened by the

I n s t a l l a t i o n

engineer.

BA. 2.44M Ballguard - C110555; BB. ’U’ Bolt - C110548; BC. Clamp Bridge - C110549; BD. Clamp Pla te - C110449; BE. M8 Nut - 5441; BF. M8 Washer - 54 45;

BG. Blanking Shield - L106020; BH. M8 x 25 Set Pin

Page 47

be shortened to suit the system

layout and also to accommodate

corner reflector sections.

2.15.2 Shortened modular grille

assemblies.

2.15.2.1 Carefully disconnect one end

support from the standard 2.44m long

grille support frame (BK).

2.15 Installation of Slimline ’M’ Decorative Grille System

nb. Reflectors removed for clarity

2.15.2.2 Cut the side support to

the required length, ensuring that

the cut ends are square and free

from burrs. Reposition the end

support and mark the fixing hole centres onto the side supports.

Drill 2 sets of 5mm diameter holes through the side supports and

secure frame using 8mm pop rivets.

The Slimline ‘M’ decorative grille system consists of standard 2.44m long modular grille assemblies which are

supported from the underside of the radiant tube. The modular assemblies are fitted in tandem along the system.

2.15.1 Standard 2.44m long modular grille assemblies

2.15.1.1 Starting at each system end vent, position the ‘U’ bolts (BB) around the radiant tube, through

the clamp bridge (BC) and secure using with M8 locknuts (BE) approximately 10mm from the ends

of the threads.

Ensure that the distance between ‘U’ bolts is 1210mm. The ‘U’ bolt assemblies should be

positioned perfectly square to ensure that the modular grille assembly lies

horizontal when fitted.

2.15.1.2 Fit 2 eggcrate grille pieces (BL) into the standard 2.44 long

grille support frame (BK).

2.15.1.3 Raise the modular grille assembly (BJ) and pass

the threaded ends of the three ‘U’ bolts through the

three sets of fixing holes.

2.15.1.3 Fit the M8 dome head nuts (BM) and

2.15.2.3 Cut grille (BL) to the required length and position into the

support frame.

2.15.2.4 Ensure that the ‘U’ bolts are positioned onto the tube to

suit the new support frame fixing positions.

2.15.2.5 The shortened modular assembly can now be fitted

to the heater using the procedure as stated in 2.15.1

washers (BF) to the threaded ends of the

‘U’ bolts. Check that the module is

secure.

A standard 2.44m long

modular grille

assembly can

BB. ’U’ Bolt - C110548; BC. Clamp Bridge - C110549; BE. M8 Nut - 5441; BF. M8 Washer - 5445; BJ. Modular Grille Assembly - L106000-SUB; BK. Support Frame - L106004;

BL. Eggcrate Grille - L106015; BM. M8 Dome Nuts - L106007

Page 48

2.16 Installation of Blanking Shields

nb. Reflectors removed for clarity

It may be necessary to prevent heat being directly emitted from certain points along the

radiated tube. Blanking plates are available in either 1250mm or 400mm sections,

which prohibit this. 2.16.1 Installation 2.16.1.1 Locate radiant tube area to be blanked. Position the ‘U’ bolts (BB) around the

radiant tube, through the clamp bridge (BC) and secure using with M8 nuts (BE). Ensure that the distance between the ‘U’ bolts is approximately 1000mm for the 1250

blanking plate or 200mm for the 400 blanking plate. The ‘U’ bolt assemblies should be positioned perfectly

square to ensure that the blanking plate lies horizontal

when fitted.

2.16.1.2 A retaining plate (BD) is

positioned on the underside of the

blanking plate (BN) at each ‘U’

bolt assembly position and

secured using M8 nuts

BB. ’U’ Bolt - C110548; BC. Clamp Bridge - C110549; BD. Clamp Plate - C11044 9; BE. M8 Nut - 5441; BF. M8 Washer - 5445; BN. Blanking Shield 1250mm - L10602 0-1;

(BE) and washers (BF).

BP. Alt Blanking Shield 400mm - L106020

Page 49

2.17 Installation of Undershield Deflectors

nb. Reflectors removed for clarity

2.17.1.3 Ensure that the distance between

the munsen rings is

approx 2360mm apart.

Repeat the above procedure for the second munsen ring.

2.17.1.4 Pass an M12 set pin (BS) through a M12 washer (BU) and

through the slot on the undershield and loosely attach the M12 locknut

(BT). Repeat for the second set pin.

2.17.1.5 Offer the undershield deflector up to the munsen rings. Locate

the set pins to the boss and tighten. Secure assembly by tightening

locknut. Repeat for second munsen ring.

An Undersheld Deflector (BR) is positioned beneath the radiant tube, usually at the first

half of the firing leg (nearest the burner), although this can be positioned at any point if

being used purely as a heat deflector for clearance purposes. The oversized munsen rings (BQ) supplied will allow the undershield deflector to move

with the expansion and contraction of the radiant tube. 2.17.1 Installation

Each undershield has two slots, 25mm in length at each end of the deflector. These

slots are used to position the munsen rings apart. Mark the first point of

the deflector on the radiant tube. Use the undershield (or a tape

measure if required) to mark the second point. 2.17.1.1 The munsen rings (BQ) are supplied

assembled. Using a flat head screwdriver

remove both screws retaining the two parts

together. 2.17.1.2 Offer one half, then

BQ. 100mm Munsen Rings - 6532; BR. Undershield 2440mm - 1350; BS. M12 x 50 Set Pin - 5501-1; BT. M12 Locknut - 5501

the other onto the

radiant tube at the first

mark with the boss

facing downwards.

Replace the screws and

tighten.

Page 50

2.18 Installation of Acoustic Enclosure

CA. Lid Assembly - 201117; CB. Side Panel Assembly - 201115; CC. Base

Assembly - L103075-SUB; CD. M6 x 16 Bolts and Washers - 5416 & 5425;

2.18.1.3 Locate fan

assembly (Y) and position in correct orientation on fan stool located

on base assembly (CC). Ensure anti-vibration mountings are used

and secure using nuts and washers supplied. Anti-vibration mountings are supplied as a kit of parts (X1 - X4).

X1-4 Anti-vibration Mount Kit - L103045-SUB; Y. Fan;

The Nor-Ray-Vac Acoustic enclosure reduces the noise from the Vacuum

fan where it is mounted inside the working area and noise is an issue. It is

constructed of noise reducing panels assembled to form a cube. The

acoustic enclosure is weatherproof and thus can be ex ternally located. 2.18.1 Dis-assembly

The acoustic enclosure is delivered pre-assembled so some dismantling

will be required to assemble the fan motor and flue.

2.18.1.1 Remove 15 off M6 bolts and washers (CD) along the lid (CA)

edge as indicated and withdraw lid

assembly (CA)

2.18.1.2 Remove 13 off

M6 bolts and

washers (CD)

along the

bottom edge

and side as

indicated.

Remove side

panel (CB)

Page 51

Dims: (hwd) 736x760x670mm Weight: 25.0kgs (excluding Fan) Part: L103101-SUB

Installation of Acoustic enclosure cont

2.18.3 Suspension instructions for acoustic enclosure 2.18.3.1 Suspension can be made from building steelwork using 12mm

diameter drop-rods (not supplied) onto each hole of the base frame. 2.18.3.2 Alternatively, the base frame can

be secured to suitable platform using

M12 bolts, nuts and washers.

2.18.2 Re-assemble 2.18.2.1 Replace side panel (CB). Refit 13 off M6 bolts and washers (CD)

along the bottom edge and side as indicated. 2.18.2.1 Replace lid (CA). Refit 15 off M6 bolts and washers (CD) along

the lid edge as indicated.

CA. Lid Assembly - 201117; CB. Side Panel Assembly - 201115; CC. B ase Assembly - L103075-SUB; CD.

M6 x 16 Bolts and Washers - 5416 & 5425; CE. 12MM All thread - (not supplied); CF. M12 Washers - (not

supplied); CG. M12 Full Nuts - (not supplied)

Page 52

2.19 Installation of the Flue Silencer

2.19.3 Vertical configuration. 2.19.3.1 Connect the one side of the flue silencer

(CH) to the flue by means of coupler (G). The

other side of the flue silencer is connected to

the remaining flue via a tube coupler (G) 2.19.3.2 Support bracketing points are

positioned along the length of the flue

silencer box.

Silicone sealant in

all the joints

G. Tube Coupler - C112120 (Ø150); T. Expansion Joint - 7532;

U. Jubilee Clip Ø150 - 7542; CH. Flue Silencer - A517360-SUB;

The Nor-Ray-Vac Flue Silencer reduces the external break-out noise from

the flue terminal. This is essential for systems installed adjacent to

residential and educational areas. It is constructed of noise reducing

baffles assembled in an enclosure. 2.19.1 Assembly

The flue silencer box has 150mm diameter spigots at either end, and can

be fitted into the fan discharge flue, utilising standard 150mm diameter

connectors supplied. The flue silencer (CH) can be fitted in the horizontal or vertical sections of

the flue. 2.19.2 Horizontal configuration. 2.19.2.1 Connect one side of the flue silencer (CH) to the expansion joint

(T) by means of a jubilee clip (U). The other side of the flue silencer is

connected to the flue via a tube coupler (G) 2.19.2.2 Support bracketing points are positioned along the length of

the flue silencer box.

Dims:

(hwd) 300 x 450 x 300mm

ø150 spigots x 140 long,

brackets 50mm

tall.

Weight: 6.0kgs

Page 53

2.20 Installation of the Fan Motor Muff

CJ - Motor Muff

2.20.1.3 Fix the muff to the

fan back bracket using 2

bolts (CK), nuts (CL)

and washers (CM) as

indicated.

The Nor-Ray-Vac Fan Motor Muff is ideal when the vacuum fan is

mounted within a plant room or unused room to dampen down the fan

motor noise. It is constructed of noise reducing panels assembled in an

enclosure. 2.20.1 Assembly

2.20.1.1 Fit the motor muff (CJ), over the motor of the vacuum fan. 2.20.1.2 Fix the muff to the fan motor stool using 4 bolts (CK), nuts (CL)

and washers (CM) as indicated.

Dims:

(hwd) L103053 - 300 x 370 x 320mm

(hwd) L103054 - 330 x 410 x 320mm

brackets 50mm

Weight:

CJ. Motor Muff - L103053 (B80/B160/B300), L103054 (BH300);

CK. M10 x 25 Set Pin - 5481; CL. M10 Nut - 5487;

CM. M10 Washer - 5480

8.0kgs

Page 54

2.21 Installation of the End Vent Silencer

Assembled EVM Silencer

AQ. EVM Outer Plate; AS. EVM Fastener; CN. EVM Silencer - L104051-SUB;

□130 x 195mm long

The Nor-Ray-Vac End Vent Silencer - reduces the break out noise from

the inrush of air into the combustion tube when installed within areas

where noise is an issue. It is constructed of noise reducing panels

assembled in an enclosure. 2.21.1 Assembly

2.21.1.1 Remove cover plate

(AQ) of the end vent

module by releasing

the 2 set screws

(AS). 2.21.1.2 Offer the

silencer (CN), up to

the cover plate of

the end vent module

and attach by fixing

the 4 set screws

(CP) and washers

(CR) to the hank

bushes in the end of

the silencer box. 2.21.1.3 Re-attach the

cover plate (AQ) to the

end vent module and fix

in position using the 2 set

screws (AS).

Dims:

(hwd)

Weight: 4.0kgs

CP. M6 x 12mm Set Pin - 5417-1; CR. M6 Washer - 5405

Page 55

3. Commissioning Instructions.

These appliances should be commissioned by a qualified engineer.

3.1 Tools Required.

The following tools and equipment are advisable to complete the tasks laid out in this manual.

Various Pozidrive Screwdrivers

Suitable alternative tools may be used.

Various Flat Head Screwdrivers

Manometer

Spanner Set

3.2 General.

Under normal working conditions it is recommended that the Nor-Ray-Vac ‘LR’ series system is regularly maintained to ensure long life and efficient operation.

Maintenance is required only once per year. In dusty or dirty conditions more frequent

maintenance is desirable. Servicing work must

setting. Refer to section 3.3.1.8

3.3.1.5 Check gas is turned on at meter and take meter gas pressure reading.

Fit pressure manometer to the inlet pressure test point on the burner furthest from the gas supply and with all burners off observe pressure reading. Turn off gas at meter and again observe reading. If pressure falls check system for leaks.

be carried out by a qualified gas service engineer.

Important

When maintaining or servicing the Nor-Ray-Vac ‘LR’ series systems:

• Never rest anything, especially ladders against heating system.

• Isolate gas and electrical supplies before commencing any service work.

3.3 Commissioning Procedure

3.3.1 Start Up Checks

3.3.1.1 Check that the installation is to the

design layout drawing and installed in accordance with the installation instructions.

3.3.1.2 Check installation electrically. Ensure

that the vacuum fan, inverter, burners and control panel are wired correctly to diagrams provided.

3.3.1.3 Ensure that each burner is electrically

disconnected at the plug/socket.

3.3.1.4 Set individual burner delay timer

dip-switches (located in each burner) to required

Injector pressure test point.

The gas pressure at the burner inlet connection must not exceed 50 mbar (20in wg).

3.3.1.6 Start the vacuum fan.

For various controllers/BMS systems it may be necessary to adjust the set point to above room temperature.

For B80/B160 and B300 fans with an inverter panel, check that the display states “rdy” (ready)

3.3.1.7 Check for correct fan rotation.

Allen Key set

Gas inlet test point

Adjustment screw under cap to set injector pressure

Page 56

In-line

BURNER 1

3.3.1.8 Burner Timer Dip-switch Adjustment

In-line

BURNER 2

In-line

BURNER 3

In the event there are more than four burners in the radiant branch,

set the dip-switches as below. 5 burners in a single branch:

Burner 1 - dip-switch 1

Burner 2 - dip-switch 1

Burner 3 - dip-switch 2

Burner 4 - dip-switch 3

Burner 5 - dip-switch 4

Each burner is fitted with an adjustable burner delay timer. The timer is adjusted using

dip-switches located on top of the timer casing. The dip-switches are labelled 1, 2, 3 and 4. These numbers correspond to the burner

positions within the radiant branch. The burner located nearest to the exhaust fan in that branch is noted as Burner 1, this

is the case irrespective of how many other burners are in that branch.

The burner directly behind burner 1 is always noted as Burner 2, the burner

directly behind Burner 2 is Burner 3 and so on finishing at the End Vent

Burner. Set the burner timer dip-switch.

End-vent

BURNER 4

For example, the timer on burner 1 is set by sliding

the white dip-switch, positioned above the

number 1, towards the number. The timer

on burner 2 is set by sliding the white

dip-switch, positioned above the

number 2, towards the

number.

Page 57

3.3.1.9 Adjust the vacuum setting

The end vent vacuum is measured by removing the protection cap on the tee piece in the air impulse line on the end vent burner and connecting a manometer.

3.4.6 Press the jog dial to enter. Rotate jog dial until ‘LSP’ is displayed. Press jog dial to enter.

3.4.7 Rotate jog dial to adjust frequency. Press jog dial to enter new value, causing the inverter to change its speed.

3.4.8 Adjust the frequency until each burner has lit.

Frequency is usually between 35 and 50 (Hz)

3.4.9 Press the ESC button twice to return the inverter to the ’rdY’ display.

3.4.10 Remove power to the system and allow fan to halt.

3.4.11 Return power to system. After a 30s delay the fan should run and a red neon should have illuminated on the rear of each burner.

3.4 B80/B160 and B300 fans ONLY

The use of an inverter on the standard B80, B160, B300 fan system allows the end vent suction to be adjusted by varying the low speed setting of the inverter within the local relay unit.

3.4.1 Ensure that electrical supply to the end

vent modules and burners in each branch are connected.

3.4.2 Check that the fan and branch dampers

are fully open and secure.

3.4.3 Ensure the controller is in a programmed

ON function and above the actual room temperature.

3.4.4 After a 30s delay the fan should run and

the inverter should be showing the motor frequency in the display.

3.4.12 Working at the radiant branch FURTHEST AWAY from the fan, observe the ignition of the burners. An amber neon should illuminate on the rear of the burner.

3.4.13 If the dip-switches have been set correctly, the burner closest to the manifold (last on branch) should ignite first followed in order by every burner towards the end vent burner.

Note: It may be necessary to temporarily break the union at a burner in order to purge the gas pipe of air.

When the branch has been running for 30 minutes check the end vent vacuum reading.

3.4.14 Re-adjust the frequency on the inverter (if necessary) until the appropriate end vent suction is achieved, this is given in the table below.

3.4.5 Press the mode button 3 times until

‘COnF’ appears on the display.

Mode button:

Switches between

control/program modes.

(Only accessible with

door open).

Standard multi-burner systems 6.25 Special considerations

Escape button:

Exits a menu or

parameter.

Jog dial:

For navigation when

turned clockwise or anticlockwise, or selection/validation

when pressed.

Single 32LR End vent only 7.5 Single 38LR End vent only 8.25 Single 46LR End vent only 9.25 Three 46LR in a single branch 5.6

System

End vent pressure

mbar

Page 58

3.4.15 Proceed to the next radiant branch closer to the fan and commission in the same manner, observing the ignition sequence of the burners and amber neon's.

3.4.16 Check the end vent vacuum reading.

3.4.17 Adjust the branch damper (if necessary) located at the end of the branch to bring the vacuum readings in line with the normal operating figure shown in the chart. Ensure that damper is locked securely after adjustment.

Adjustment instruction for branch damper. 1 Loosen grub screw (A). 2 Turn adjustment lever (B). 3 Position of damper blade is indicated by position of bent adjustment lever. 4 Tighten grub screw (A) to secure damper position.

3.4.18 Repeat for any further branches (where necessary), moving closer to the fan as each branch is completed.

The vacuum setting procedure is now complete.

3.5 BH300 fans ONLY

(and fans controlled by NRV ‘logic’ driven LRU’s with no inverter)

End vent vacuum settings are made firstly by means of adjusting the damper at the vacuum fan inlet, this brings the end vent with the lowest reading to the normal operating vacuum.

The dampers on each branch can then be adjusted to bring the vacuum readings in other branches to the normal operating figure.

Ensure that all dampers are locked securely after adjustment.

3.5.1 Ensure that each burner is electrically disconnected at the end vent module plug/ socket.

3.5.2 Check vacuum fan inlet and branch dampers are fully open in the first instance and secure.

3.5.3 Ensure the controller is in a programmed ON and above the actual room temperature.

The fan inlet damper is integral to the fan inlet condensate tee piece. 1 Loosen grub screw (A). 2 Turn adjustment lever (B). 3 Position of the damper blade is indicated by position of bent adjustment lever. 4 Tighten grub screw (A) to secure damper position when finished.

3.5.4 After a 30s delay the fan should run.

3.5.5 Working at the end vent burner FURTHEST AWAY from the fan, measure the vacuum pressure and adjust the fan inlet damper to obtain over 8.7 - 10 mbar (above

3.6in wg) WHEN COLD.

Page 59

3.5.6 Remove power to the system and allow fan to halt.

3.5.7 Ensure that each burner is electrically re-connected at the end vent module plug/

3.6 Final Commissioning.

3.6.1 Check that the burner injector pressures are zero ± 0.25 mbar (±0.1in wg). Adjust if necessary.

socket.

3.5.8 Return power to system. After a 30s delay the fan should run and a red neon should have illuminated on the rear of each burner.

3.5.9 Working once more at the radiant branch FURTHEST AWAY from the fan, observe the ignition of the burners. An amber neon should illuminate on the rear of the burner.

3.5.10 If the dip-switches have been set correctly, the burner closest to the manifold (last on branch) should ignite first followed in order by every burner towards the end vent burner.

Note: It may be necessary to temporarily break the union at a burner in order to purge the gas pipe of air.

Allow the branch to run for 30 minutes.

3.5.11 Recheck the end vent burner FURTHEST AWAY from the fan, measure the vacuum pressure. Adjust the branch damper (if necessary) to obtain the figure shown in the table below.

End vent

System

pressure

mbar

Standard multi-burner systems 6.25 Special considerations Single 32LR End vent only 7.5

Single 38LR End vent only 8.25

3.6.2 Check operation of thermostat controllers

a number of times, allowing the burner ignition cycle to complete each time, checking that each burner relights.

3.6.3 With all burners firing check the inlet gas

pressure at the burner furthest away from the gas supply.

The minimum inlet pressure is 17.5mbar for G20 (Nat Gas), 20mbar for G25 (Nat Gas) and G31 (Propane) and 25mbar for G30 (Butane).

The difference between gas pressure at the burner, with all the burners on and all the burners off should not be more than 2.5 mbar (1in wg).

3.6.4 Take gas consumptio n meter readings for

each separate NRV system or building heated ensuring all other loads are off.

3.6.5 After the system has reached equilibrium:

take the following measurements.

a The flue gas temperatures entering the

Single 46LR End vent only 9.25 Three 46LR in a single branch 5.6

vacuum fan. The flue gas sample point located on the vacuum fan tee is used.

b The surface temperature of the underside of

3.5.12 Repeat for any further branches (where necessary), moving closer to the fan as each branch is completed.

The vacuum setting procedure is now complete.

the tube at the end of each radiant branch.

c The surface temperature of the underside of

the tube at a point directly underneath each combustion chamber suspension lug.

3.6.6 Reset thermostat controllers to required

setting.

3.6.7 Complete service report sheet.

Adjustment

screw under cap

to set injector

pressure

Injector pressure

test point.

Page 60

3.7 Typical Unequally Balanced System Layout

End vent

Pressure mbar

System

Standard systems - shown 6.25

Single 32LR End vent only 7.5

Single 38LR End vent only 8.25

Single 46LR End vent only 9.25

Special considerations

Three 46LR in a single branch 5.6

Page 61

4. Servicing Instructions.

These appliances should be serviced annually by a competent person to ensure safe and efficient operation. In exceptional dusty or polluted conditions more frequent servicing may be required. The manufacturer offers a maintenance service. Details available on request

4.1 Tools Required.

The following tools and equipment are advisable to complete the tasks laid out in this manual.

Leather Faced Gloves

Large Adjustable Spanners or 22, 26 & 27mm Spanners for Gas Flex.

Various Pozidrive Screwdrivers

4.2 Burner Exploded Views. Figure 6.a. LR Burner Head

6 Burner head casting – L100103-SUB

7 Burner port insert – L100155

8a Flame retention grid – L100171

8b Flame retention mesh – L100177

8c Flame retention plate – L100176

9 Air shutter plate - see selection chart

10 Burner jet - see selection chart

11 Electrode assembly – L100401

23 ½” plug – L100202

37 Set pin M4 x 6 – 5326-1

Spanner Set

Suitable alternative tools may be used.

Various Flat Head Screwdrivers

Allen Key set

Soft Brush

Assembly for LR12 - 18

Part assembly for

LR24 - 46 ONLY

Page 62

Figure 6.b. LR Burner

31 34

39 37

19 18

1 Control housing base plate – L102001 2 Control housing lid – L102009

3 Full sequence gas controller – 2015

4 Multi functional gas valve – C111513 plus 900041 5 Air filter – L102013

6 Burner head casting – L100103-SUB

7 Burner port insert – L100155

8 Flame retention grid – L100171

9 Air shutter plate - see selection chart

10 Burner jet - see selection chart

11 Electrode assembly – L100401

12 Mains input filter – 201292

Mains lead (not shown) – 2125

13 Air pressure switch (EV only) – L104039

14 Bulkhead compression fitting (EV only) – L104073

15 Delay timer – L102025-SUB

16 Inline Socket (EV only) – 3123-5

Inline burner plug (EV only - not shown) – 3124

17 Wiring harness – E200067

18 Red neon light – 2180 19 Amber neon light – 2175

20 Gas inlet connection pipe ½” x 4” – 2360 21 Gas outlet inlet connection pipe ⅜” x 2½” – 2314-1

22 ½” x ⅜” reducing bush – 2320

23 ½” plug – L100202

17 41

43 35

24 Valve mounting bracket – L102020

25 Pressure switch bracket – L200025

26 Grommet (gas supply) – B200500

27 Grommet (13mm) – 2878 28 Burner gasket – L102032

29 Silicone gasket – L102031

30 Slide latch – L100200

31 Latch clip – L100201

32 Push clip – C110714

33 Wing nut – C111700

34 Set pin M4 x 12 – 5325

35 Set pin M4 x 10 – 5314

36 Set pin M5 x 10 – 5363 37 Set pin M4 x 6 – 5326-1 38 Washer M4 – 5322 39 Nut M4 – 5315 40 Torque Screw - 201093

41 Silicone tubing (EV only) – L100180-SUB 42 Silicone tubing (EV only) – L100181-SUB

43 Plastic tee (EV only) – L104200 44 Tee cap (EV only) – L104201

Page 63

4.3 Vacuum fan

Inspect fan and flue ductwork for any contamination.

Inspect expansion joints for damage and replace if necessary.

4.4 Tubes

Inspect radiant tubes and fittings internally. If there is any appreciable build up of dust or deposits the tubes should be cleaned internally.

If corrosion is present replace as necessary.

Note It may be necessary to determine whether chlorinated hydrocarbons are being used by the client.

4.5 Tube couplers

Check for tightness. Inspect for evidence of holes and cracks and replace if necessary.

4.6 Reflectors

Check for overlaps and re-adjust if necessary. The reflectors may be cleaned with a soft cloth and detergent in water.

4.7 Condensate trap

Inspect for dirt and scale and clean if necessary.

4.8 Burner electrodes

Check ceramic visually for build up of carbon or cracks. Check the spark distance and position of the electrodes relative to the burner head, replace if necessary (see fig.7).

4.9 Burner head

Check condition of burner head

insert and flame retention grid and replace if necessary.

4.10 Filter

Replace if contaminated with dirt.

4.11 Combustion Chamber Viewing Window

Window should be clean and free from cracks. Replace if necessary.

Re-commission system after servicing (see section.3)

Figure 7. Burner Electrode Details

3.5mm

18mm

13mm

Page 64

5. Spare Parts.

Required Spares

In order to aid troubleshooting and servicing we recommend that the components shown in this section should be stocked.

Item

Ignition Controller

Nat Gas Valve Twin Solenoid 220/240

Valve Mini Harness

Mains Input EMC Filter

Part No. Description

2015

C111513

900041

201292

Note Any spare part components that are not approved by AmbiRad could invalidate the approval of the appliance and validity of the warranty.

Item

Amber Neon (Burner On)

Red Neon (Mains On)

Inline Burner Socket

Part No. Description

L104039 Pressure Switch

2175

2180

3123-5

Rectification Lead

Mains Input Cable

L100401 Ignitor Assembly

2243-1 HT Spark Lead

2243-2

2125

Inline Burner Plug

Vacuum Test Nipple

Main Harness End Vent In-line

3124

L104200

L102026 Burner Timer

E200067 E200068

2104 Lockout Relay L102013 Burner Air Filter

2197 Webber Valve

Lockout Relay Base

2108

Page 65

Fan B80 B160 B300

Part No. Description Item Part No. Description

Item

Burner Head

L102032 Burner Gasket

Assembly LR12-18 LR24-46

Flame Retention

L100155 Ceramic Insert

Grid LR12-18 LR24-46

A523500 Mica Window

C110350 Window Gasket

201760 201761 201762

Sight Glass Cover

End Vent Module

Inverter

1.5kW B80/B160

2.2kW B300

L100102-SUB12-18 L100102-SUB

L100175-SUB L100171

A571202

EVM

900088 900089

Fan BH300

100mm (4”) Tube Coupler

150mm (6”) Tube Coupler

Combustion Chamber

Combustion Chamber Reflector

201763

C112110

C112120

L101020-SUB

L105050

Contactor/O’load BH300

Fan Expansion Joint

Suspension Bracket

Reflector Support Bracket

900088

7532

7542 Jubilee Clip

C110500-SUB

L201008-SUB

Standard Reflector

L105024

6524 Speedlinks

Page 66

NRV LR Injector/Air Shutter selection chart

Gas Burner

12 3.6 L100336 13 L100322 14.5 L104102 18 4.4 L100544 17 L100321 16 L104101

Natural

G20

Natural

G25

24 4.9 L100549 19.5 L100320 24 L104100 32 5.4 L100554 22 L100314 27 L104093 38 5.8 L100558 24 L100316 32 L104092 46 6.3 L100563 26.5 L100318 - 12 3.7 L100537 13 L100322 14.5 L104102 18 4.6 L100546 17 L100321 16 L104101 24 5.2 L100552 19.5 L100320 24 L104100 32 5.8 L100558 22 L100314 27 L104093 38 6.3 L100563 24 L100316 32 L104092 46 6.9 L100569 26.5 L100318 - -

Jet Size dia mm

Part number

Sutter Size dia mm

Part number

EVM Orifice Plate dia mm

Part number

Butane

G30

Propane

G31

12 2.6 L100526 13 L100322 14.5 L104102 18 3.2 L100532 17 L100321 16 L104101 24 3.7 L100537 19.5 L100320 24 L104100 32 4.2 L100542 22 L100314 27 L104093 38 4.6 L100546 24 L100316 32 L104092 46 5.1 L100551 26.5 L100318 - 12 2.9 L100529 13 L100322 14.5 L104102 18 3.5 L100535 17 L100321 16 L104101 24 4.0 L100540 19.5 L100320 24 L104100 32 4.4 L100544 22 L100314 27 L104093 38 4.8 L100548 24 L100316 32 L104092 46 5.2 L100552 26.5 L100318 - -

Page 67

6. Fault Finding Guide.

Symptoms Possible causes Remedy

Vacuum fan is running but there is no power at burner. Neon lights are off.

Red neon comes on but ignition sequence does not start and amber neon remains off.

Red neon comes on. Amber neon comes on for ignition period; then amber neon goes off.

Red neon comes on. Amber neon comes on for ignition period, burner lights for a short time and then goes out. Amber neon off.

End vent vacuum too low (ie below

6.25 mbar (2.5in wg). Check section 3, commissioning for exact vacuum details.

Thermostat is satisfied. Check to see that thermostat is calling for heat. No power at burner. Check for 240V supply.

Blown fuse in supply to heater. Check and replace if necessary. End vent vacuum too low. Vacuum at end vent should be 6.25 mbar

Air pressure switch on end vent burner not opening.

3 way air valve (if fitted) in end vent burner not opening.

No power out from end vent burner. Check for loose or broken wire or faulty relay.

Loose or broken leads to full sequence gas controller.

Fault in full sequence gas controller. Replace. No ignition spark. Check for loose or broken high tension lead to

Fault in full sequence gas controller. Replace. Insufficient gas supply to burner. Check service cock is open and gas pressure

Gas solenoid valve not opening. Check for loose or broken wires to the gas

Injector pressure not set at zero. Check and adjust. Incorrect aeration. Check that air shutter plate on mixing chamber

Flame probe faulty or lead detached. Check for broken ceramic.

Fault in sequence gas controller. Measure flame current.

Polarity of line and neutral incorrect. Check for correct polarity of the electrical

Burner earth is poor. Check and ensure burner is correctly earthed. Full sequence gas controller faulty. Replace. Incorrect aeration. Check that air shutter plate on mixing chamber

Branch damper closed or broken. Open branch damper until end vent vacuum is

Fan rotation incorrect. Reverse two phase wires on 3 phase motors. Fan speed wrong. Check voltage at motor. Replace if necessary. Fan impeller loose or defective. Tighten or replace if necessary. Restriction to fan inlet. Clear restriction, repair flue duct. Air leaks into system via poor joints. Replace defective tube couplers gaskets or

Insufficient fall of system towards fan allowing condensate blockage.

Non return valve sticking open on condensate trap assembly.

(2.5in wg). Check for air leaks on burner. Check and replace if necessary.

Check and replace if necessary.

Check and repair.

spark electrode. Check spark gap and position for spark electrode Check ceramic is not cracked. Check for loose earth wire connection on full sequence gas controller.

is available at inlet to gas valve.

valve. Check for adequate end vent vacuum. Replace valve if necessary.

is correctly positioned.

Check for correct position of flame probe.

The minimum signal is 3μA (DC).

supply.

is correctly positioned.

6.25 mbar (2.5in wg). Replace damper if necessary.

acoustic joints. Reinstate system fall.

Clean valve or replace if damaged.

Page 68

7. Replacing Parts.

7.1 Removal of burner assembly.

a Disconnect electrical supply at burner mains

inlet connection. b Turn-off gas supply at service cock and

disconnect union.

b1 On EVM burners, remove the vacuum tubes by releasing the two compression fittings (14).

c Release the slider latches (30) from the underside of the burner base plate (1).

i Remove the burner heat shield. j When replacing do so in the reverse order

ensuring that the gasket between the burner heat shield and combustion chamber (28) is undamaged or replaced.

k Check for gas soundness.

7.2 Removal of gas valve.

a Remove burner assembly from combustion chamber as detailed in 7.1.

b Secure burner head (6) and unscrew gas inlet pipe (21).

c Remove burner set screws (37) and valve bracket set screws (36) from burner base plate.

d Pull lid (2) apart and upwards from base (1). Lid is attached to back plate via 2 screws (34).

e Remove lid by unscrewing set pins (34) from back of base plate.

f Remove spark electrode assembly (11) (see section 7.7)

g Release and remove the four set screws (40) from the combustion chamber flange. Retain combustion chamber gasket (28).

h Lift burner clear of combustion chamber and withdraw.

d Withdraw burner head and valve from base plate. Retain burner gasket for later (28).

e Secure burner head (6) and unscrew gas valve (4).

f Replace in reverse order.

Page 69

7.3 Filter Replacement.

a Release the slider latches (30) from the

underside of the burner base plate (1).

b Pull lid (2) apart and upwards from base(1). c Unscrew wing nut fastener (33).

c Pull lid (2) apart and upwards from base (1). d Disconnect JST connection (3a).

e Disconnect ignition wire from controller (3b). f Release three push clips (32) from controller

fixing holes.

g Remove controller (3)

d Slide filter (5) out of location brackets. e Replace in reverse order.

7.4 Controller Replacement

a Disconnect electrical supply. b Release the slider latches (30) from the

underside of the burner base plate.

h Replace in reverse order.

7.5 Pressure Switch Replacement (EVM ONLY).

a Disconnect electrical supply. b Release the slider latches (30) from the

underside of the burner base plate.

c Pull lid (2) apart and upwards from base (1). d Disconnect both silicone tubes (42 & 43) from

pressure switch (noting connection orientation).

Page 70

e Disconnect three electrical cables from pressure switch (noting connection orientation).

f Remove fixing screws and nuts from the pressure switch bracket and withdraw.

g Remove retaining screws from bracket to pressure switch and remove unit

h Replace in reverse order.

7.6 Sequence Timer Replacement.

a Disconnect electrical supply. b Release the slider latches (30) from the

underside of the burner base plate.

c Pull lid (2) apart and upwards from base (1). d Remove controller as described in section 7.4 e Disconnect electrical connection from the

timer. f Remove fixing screws from timer bracket and

withdraw.

g Remove timer from the insulation wrap and remove unit.

h Replace in reverse order.

7.7 Electrode Assembly Replacement.

a Disconnect electrical supply. b Release the slider latches (30) from the

underside of the burner base plate.

c Pull lid (2) apart and upwards from base (1). d Remove fixing screws (37) from electrode

mounting flange (11).

e Carefully withdraw electrode assembly from burner - noting electrode orientation.

f Replace in reverse order.

7.8 Injector Replacement. (See figure 6a)

a Turn off gas and disconnect electrical supply. b Release the slider latches (30) from the

underside of the burner base plate (1).

c Pull lid (2) apart and upwards from base (1). d remove fixings screws (37) and air shutter

plate (9) from top of burner casting. e Remove plug (23).

Page 71

f Unscrew brass jet (10) inside mixing chamber using 8mm allen key and withdraw through 1/2in BSP hole.

b Unscrew dome nuts (47) and spring washers (48). Remove sight glass cover (49), gasket (50) and mica window (51).

c Replace in reverse order as shown ensuring components are re-assembled in correct order.

1. Mica Window A523500

2. Window Gasket C110350

3. Sight Glass Cover A571202

4. Spring Washers

5. Dome Nuts L101040

A315110

g Replace in reverse order.

7.9 Combustion Chamber V i e w i n g W i n d o w Replacement.

a Turn off the system including the vacuum fan.

Page 72

8. User & Operating Instructions.

8.1 To Start the Heater

1. Ensure that gas supply is turned on at

each burner.

2. Switch on electrical supply to heaters.

3. Ensure that the controls are correctly set i.e.;

• Clock is correctly set.

• Heater program is correctly set.

• Required room temp is correctly set

4. The vacuum fan will operate and at the

same time the red neon lights will illuminate at all burners. After 10 seconds the burners closest to the exhaust fan in each radiant branch will light, with both red and amber neons illuminated. After a further 25 seconds the next burner in line within each radiant branch will light and after a further 25 seconds the end vent burner will light.

5 If the lighting up sequence fails and lockout

occurs press the lockout reset button (if available), or switch off the electrical

supply and restart after 40 seconds. If

lockout occurs three times consecutively switch off and isolate the gas and electricity supplies.

Contact the AmbiRad Service department.

8.2. To Switch Off Heater

1. Switch off electrical supply to the heater. The burner will stop and the fan will shut off.

2. If the heater is to be switched off for periods in excess of one week it is highly recommended that both the gas and the electrical supplies are turned off.

8.3. Routine Maintenance between Service Intervals

After ensuring that the heater is cold and mains electric isolated, cleaning of the reflectors with a soft cloth and a mild detergent (non solvent based cleaners only) in water can be undertaken.

Additional removal of dust from the radiant tubes, burner and heat exchanger can be undertaken.

8.4 Frequency of Servicing

The manufacturer recommends that to ensure continued efficient and safe operation of the appliance, the heater is serviced annually by a competent person e.g. every year in normal working conditions but in exceptional dusty or polluted conditions more frequent servicing may be required.

The manufacturer offers a maintenance service.

Details are available on request. For Service requirements, please contact

AmbiRad. For further technical and service support

visit our Support Information Database at www.s-i-d.co.uk

Note This notice must be fixed alongside the electrical service switch. On some systems only the end vent burner contains a delay timer. In this instance the inline burners will light simultaneously and the end vent burners will light after an 80 seconds delay.

AmbiRad Limited Fens Pool Avenue Brierley Hill West Midlands DY5 1QA United Kingdom.

Telephone 01384 489700 Facsimile 01384 489707 Email [email protected] Website www.ambirad.co.uk Technical Support www.s-i-d.co.uk

AmbiRad is a registered trademark of AmbiRad Limite d. Because of continuous product

innovation, AmbiRad reserve the right to change product specification without due notice.

Document reference number GB/NRV/193/0711